Fluent A

Flare Gas Meter 160-II
Ultrasonic Flare Metering System
User Manual
72.120.606/D
FLUENTA © 2010 www.fluenta.com info@fluenta.com sales@fluenta.com support@fluenta.com

Introduction
Fluenta – Flare Gas Meter 160

User Manual
TABLE OF CONTENTS
Table Of Contents .......................................................................................... 2

1. Introduction .......................................................................................... 3
1.1 It all began in 1982 ........................................................................................... 4
1.2 The Fluenta FGM 160 ......................................................................................... 5
1.3 Fluenta Quality Assurance .................................................................................. 6
1.4 Company and Contact Information ...................................................................... 6
2. Service Offers ........................................................................................ 7
2.1 Service & Commissioning ................................................................................... 8
2.2 FGM 160 Training Courses ................................................................................ 10
3. Main Data ............................................................................................ 13
3.1 Utility Consumption Data.................................................................................. 14
3.2 FGM 160 Data Sheet ........................................................................................ 16
3.3 Weight Data Sheet .......................................................................................... 22
4. Technical Description .......................................................................... 24
4.1 Functional Description ...................................................................................... 25
4.2 Flow Calculations............................................................................................. 36
4.3 Cable Description ............................................................................................ 42
5. Handling, Installation and Storage ...................................................... 47
5.1 Preservation, Packing, Unpacking and Storage Procedure ..................................... 48
5.2 Installation & Hook-Up Instructions ................................................................... 53
8. Space Requirements for the TFS ....................................................................... 92
5.3 Hazardous Area Installation Guidelines .............................................................. 93
6. Operating Instructions ........................................................................ 99
6.1 Operating Instructions .................................................................................... 100
6.2 DCS Modbus Interface Specifications ................................................................ 125
6.3 HART Output Interface Specification ................................................................. 149
6.4 Operator Console Description ........................................................................... 165
7. Maintenance Instructions .................................................................. 190
7.1 Maintenance Procedure ................................................................................... 191
8. Spare Parts List ................................................................................. 197
8.1 SPIR ............................................................................................................. 198
9. Drawings ........................................................................................... 199
9.1 General Arrangement Flow Element - TFS ......................................................... 200
9.2 General Arrangement Sensor Unit – TFS with Lemo Insert Cable Connector ........... 201
9.3 Transducer Holder, 2”, ANSI 150# RF ............................................................... 202
9.4 Field Wiring Diagram, 1 System ....................................................................... 203
9.5 Field Wiring Diagram with Foundation Fieldbus, 1 System ................................... 204
9.6 Field Wiring Instructions, 1 System .................................................................. 205
9.7 Block Diagram, 1 System ................................................................................ 209
9.8 General Arrangement Field Computer ............................................................... 210
10. Revision History ................................................................................ 211
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Introduction
1. INTRODUCTION
· Fluenta is the world leader in ultrasonic flare metering, headquartered in

Bergen, Norway. Fluenta have more than 850 ultrasonic flare metering systems
in operation worldwide. Fluenta have offices in Paris, Dubai and Houston.
· The Fluenta Flare Gas Meter is the most robust and accurate flare meter on the
market today able to cover higher velocity ranges than any other flare meter. It
is an essential monitoring tool for E&P operators.
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Introduction
1.1 It all began in 1982
1982 – 1986.
The Fluenta Flaregas meter was developed by Christian Michelsen Institute
1985.
Christian Michelsen Institute founded Fluenta
AS
1987.
First Fluenta Flaregas meter in operation.
2001.
Roxar acquires Fluenta AS.
2007.
Roxar’s management board makes a
strategic decision to divest its flaring
business.
9th May 2007.

The new owners of the flaring business establish
the new Fluenta AS. Personnel with a total of almost
100 years of experience with ultrasonic flare measurement
follow the flare business from Roxar to Fluenta.
2009.
Fluenta is a worldwide organisation with offices in Paris, Dubai,
Malaysia, Houston and Bergen.
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Introduction
1.2 The Fluenta FGM 160
· The FGM 160 is an Ultrasonic meter based on Time-of-Flight transit time

measurement. It is non-intrusive for all pipe diameters, and has a
measurement uncertainty of ±2.5-5% over the standard flow velocity range of
0.03-100m/s. An extended flow range of up to 120m/s and improved
uncertainty is feasible depending on process parameters. Contact Fluenta Sales
Dept. for more information.
· The FGM 160 flow computer is field mounted and can be fully operated from
any location when connected via Modbus to the unique
software operator console.
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Introduction
1.3 Fluenta Quality Assurance
Quality Management System (QMS)

The QMS covers the design and production of
the company´s products and services.
Health, Safety & Environment Management

System (HS&E)
The purpose of Fluenta's HS&E Management
System Manual is to describe the overall
HS&E standards and goals in Fluenta.
ISO 9001:2008 Certified

Fluenta AS has implemented and maintains a
Quality Management System which fulfills
Nemko's provisions for Management System
Certification and the requirements
of the following standard NS-EN ISO 9001:2008.
1.4 Company and Contact Information
Name : Fluenta AS
Org no: NO 991 199 098 MVA
Mailing address : PO Box 115 Midtun, 5828 Bergen, Norway
Visit address : Sandbrekkeveien 85, 5225 Nesttun, Norway
Invoicing address : P.O. Box 323, 5501 Haugesund
Phone : +47 55 29 38 85
Fax : +47 55 13 21 60
Web address : www.fluenta.com
Sales E-mail : sales@fluenta.com
Support E-mail : support@fluenta.com
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Service Offers
2. SERVICE OFFERS
2.1 Service & Commissioning ............................................................................... 8

1. Local Capability .............................................................................................. 8
2. Commissioning .............................................................................................. 8
2.1 Use of Meter Simulator to test the communication interface with the meter......................... 8
2.2 Installation (Pre commissioning) ............................................................................................... 8
2.3 Commissioning .......................................................................................................................... 8
2.4 Commissioning Spare Parts ....................................................................................................... 9
3. Service agreements ........................................................................................ 9
3.1 Assistance from the Fluenta Support Team .............................................................................. 9
3.2 Tailor-made Preventive Maintenance and Calibration Program............................................... 9
3.3 Regular Maintenance and training ............................................................................................ 9
3.3.1 Training .............................................................................................................................. 9
3.3.2 Maintenance .................................................................................................................... 10
3.4 Co-operation synergies leading to a priority customer status ................................................ 10
2.2 FGM 160 Training Courses ............................................................................ 10
1. Operator course ........................................................................................... 10
1.1 Content .................................................................................................................................... 10
1.2 Recommended equipment for the course (at additional cost) ............................................... 10
1.3 Duration ................................................................................................................................... 11
2. Extended operator course ............................................................................. 11
2.1 Content .................................................................................................................................... 11
2.2 Indispensible equipment for the course ................................................................................. 11
2.3 Duration ................................................................................................................................... 11
3. Field training course ..................................................................................... 12
3.1 Goal.......................................................................................................................................... 12
3.2 Content .................................................................................................................................... 12
3.3 Minimum requirements for the course (at additional cost) ................................................... 12
3.4 Duration ................................................................................................................................... 12
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Service Offers
2.1 Service & Commissioning

Fluenta has more than 20 -years of field experience worldwide.
Fluenta’s technical staff will provide your personnel with the key skills
needed to realize t he full potential of your investment in Fluenta
products.
The meter is delivered with a warranty as described in Section 1.10 of
the quotation document - Warranty. The meter warranty is valid only if
Fluenta personnel are called out for commissioning and s ervice of the
meters.
Fluenta has established a priority customer program for customers
entering into a service agreement with us. Among benefits from this
program are minimized downtime, remote support and discounts on spare
parts and training courses. This program is presented in detail in section
1.3 Service Agreement. Alternatively commissioning and service
activities can be ordered on an as -needed basis.
1. Local Capability
The Fluenta Support team has a wide network of service engineers and
technicians. All engineers are trained and certified according to our
internal training program, assuring our clients a fully competent and
professional assistance.
The use of the local engineers minimizes the mobilization time and takes
advantage of their knowledg e of local conditions and language.
2. Commissioning
The system shall be installed and commissioned as per the detailed
instructions in our Installation and Hook -Up Manual.
This work can be divided into several phases:
2.1 Use of Meter Simulator to test the communication

interface with the meter
· Testing of meter interface to DCS or other customer systems
· Reduces time spent at site for configuring and programming of DCS
interface
2.2 Installation (Pre commissioning)

· Fluenta offers to supervise mechanical and electr ical installation
· Eliminate time consuming installation errors prior to the
commissioning
2.3 Commissioning
· Service Console software installation and configuration (if not already
pre- installed)
· Power- up checks
· Configuration and set -up of parameters
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Service Offers
· Communicat ion verification checks between field computer and client

DCS system
· Check of the analog in/outputs (where applicable).
· Calibration and configuration checks.
· Validation of meter output at meter start -up
Fluenta service rates are detailed in section 2.1
2.4 Commissioning Spare Parts

The complete spare parts price list is provided in attachment Spare Parts
List. The parts recommended for commissioning and operation of the
meter are specified in this list.
3. Service agreements
Fluenta recommends that commissioning and service are handled by
Fluenta qualified personnel through a mutual beneficial service program.
End user benefits for having signed a service agreement with Fluenta will
include:
3.1 Assistance from the Fluenta Support Team

The Fluenta support team assi sts clients worldwide with all tasks related
to Fluenta Metering Products. We provide assistance during
commissioning, scheduled maintenance, service, upgrade,
troubleshooting and at all other stages of Life Cycle Management.
3.2 Tailor-made Preventive Maintenance and Calibration

Program
This custom made program will minimize meter downtime and ensure
that the meter(s) operates within the stated accuracy and repeatability.
The program constitutes of scheduled site visits paired with remote
support from Fluenta office.
3.3 Regular Maintenance and training

Fluenta can offer a service contract to customers who want to protect
their investment and secure trouble free operation in co -operation with a
specialist team. Proper maintenance and well - trained operators are
impo rtant factors in ensuring optimal performance.
3.3.1 Training
One of the critical success factors is the proper training of the personnel
directly involved with the equipment. This is also valid for technicians
and engineers using the data from it. The training program can be
designed to comply with customers requirements. Normally a
combination of practical “on -site” training on one of Fluenta’s training
spools and classroom training gives the best results. The objective of the
training program is to ensure that the technicians and engineers that are
to use the equipment will understand the principle behind the
technology, and that they will become able to operate the gear in an
ample way.
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Service Offers
3.3.2 Maintenance
We recommend that Fluenta Metering Products are included in t he Clients
preventive maintenance program. Typical activities during check up are
calibration, evaluation of system performance and data validation.
3.4 Co-operation synergies leading to a priority customer

status
When entering into a service contract with F luenta, you will optimize
system accuracy and minimize operational interruptions. The users and
operators will be updated on technology issues and be regularly trained
to ensure trouble free operation.
You will automatically achieve status as a priority cu stomer with free
phone and e-mail support, priority call-out and discounted rates on work
beyond the service agreement.
2.2 FGM 160 Training Courses
The goal of the FGM 160 training courses is the technical introduction to
FGM 160, including operator consol e training and the usage of docklight.
The participants will be able to diagnose the system and make
conclusions of the proper actions for troubleshooting.
At the end of the course, the operator will possess technical knowledge
to perform troubleshooting a nd diagnostic, thus be able to provide
Fluenta with critical information in order to effectively introduce changes
to enhance overall system performance.
1. Operator course
1.1 Content
· Standard presentation (included in the price)

· Document template and course contents (included in the price)
· Demonstration of the FGM 160 remote desktop functionality
(equipment for training needed)
· Training on the usage of operator console and DockLight
· Final Exam
1.2 Recommended equipment for the course (at additional

cost)
· Operator console
· Moxa communication hardware: Moxa Uport 1150/Moxa nport 1250
· DockLight license
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Service Offers
1.3 Duration
· 1 – 2 days (depends on number of participants)
2. Extended operator course
2.1 Content

· Document template and cou rse contents (included in the price)
· Demonstration of the FGM 160 remote desktop functionality
(equipment for the training required)
· Training on the usage of operator console and DockLight
· Final Exam
2.2 Indispensible equipment for the course
· Operator Console
· Moxa communication hardware (optional)
· Zero point calibration box
· Docklight License
· Extended course documentation and templates
Note: This course requires a s igned agreement with each of the

participants, the implicati on of the agreement is that the knowledge from
the course content can only be used for the installation which has
applied for the course.
Moreover, the participants are not licensed to change transducers, and
the consequence of doing that will violate the warranty agreement.
Additionally, a recertification within this program has to be done every
3 r d year.
2.3 Duration
· 2 – 3 days (depends on number of participants)
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Service Offers
3. Field training course
3.1 Goal
Brief technical introduction to FGM 160, including operato r console

training
3.2 Content
· Field training (“I n situ” customers’ location)

· Document template and course contents (included in the price)
3.3 Minimum requirements for the course (at additional

cost)
· Operator Console
· Moxa communication hardware
· Docklight License
3.4 Duration
· 1 day
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Weight Data Sheet
3. MAIN DATA
3.1 Utility Consumption Data
3.2 FGM 160 Data Sheet
3.3 Weight Data Sheet
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Weight Data Sheet
3.1 Utility Consumption Data
1. Purpose ...................................................................................................... 15
2. Abbreviations/Definitions .............................................................................. 15
2.1 Abbreviations:.......................................................................................................................... 15
2.2 Definitions: .............................................................................................................................. 15
3. Utility Consumption Data............................................................................... 15
4. Nominal Power Consumption ......................................................................... 15
5. Maximum Power Consumption ....................................................................... 15
6. References .................................................................................................. 15
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Weight Data Sheet
1. Purpose
This document gives the utility consumption requirements for the Fluenta Flare Gas
Meter, FGM 160.
2. Abbreviations/Definitions
2.1 Abbreviations:
FGM - Flare Gas Meter
2.2 Definitions:
N/A.
3. Utility Consumption Data

The FGM 160 utilizes 24 VDC supply voltage.
4. Nominal Power Consumption

Under normal circumstances the FGM 160 will consume approximately 250 mA with a
supply voltage at 24 VDC. Accordingly, the nominal power consumption will be
approximately 6 VA or 6 W.
5. Maximum Power Consumption

In a scenario where all ports within the system are being used and the system is fully
loaded, maximum power consumption will not exceed 13 VA or 13 W.
6. References
N/A.
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Weight Data Sheet
3.2 FGM 160 Data Sheet

1. Purpose ...................................................................................................... 17
2.1 Abbreviations:.......................................................................................................................... 17
2.2 Definitions: .............................................................................................................................. 17
3. General ....................................................................................................... 17
4. Operating Limits .......................................................................................... 17
5. Design Limits ............................................................................................... 18
6. Electrical Data ............................................................................................. 18
7. Functional Characteristics .............................................................................. 19
8. Measuring Section ........................................................................................ 19
9. Field Computer ............................................................................................ 20
10. Operator Console ......................................................................................... 20
11. References .................................................................................................. 21
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Weight Data Sheet
1. Purpose
This document specifies the general, environmental, electrical and operational data of
the Fluenta Flare Gas Meter, FGM 160.
2.1 Abbreviations:
TFS Transducer Full Size
2.2 Definitions:
EEx-d/e FGM160 Field Computer Electronics Unit in EEx-d explosion proof enclosure
and connection housing in EEx-e enclosure.
3. General
Transducer
3.1 Ultrasonic / Time-of-flight / TFS / Wetted but non-intrusive
Type
Transducer
3.2 STANDARD OPTIONAL
Material
Titanium / Inconel
Titanium / Hastelloy
SS316 / Titanium
Titanium / 6Mo
Titanium / Duplex
ATEX: Nemko 07ATEX1160
CSA: CSA2241432 - Class I Div 2
3.3 Certification
GOST-R: 8468425
GOST-K: KZ7500361.01.01.16570
Field
Ex de [ia] IIC T6, Tamb: -40 °C to + 60 °C
Computer
Ultrasonic
Ex ia IIC T4-T6 (Zone 0)
Transducers
Flare Gas Measurement and other low pressure hydrocarbon gas
3.4 Service
flow measurements
4. Operating Limits
4.1 Pipe Sizes STANDARD OPTIONAL

2" to 72" 74" to 82"
4.2 Temperature
Ambient
Temperature -40 to +140 °F (-40 to +60 °C)
(Field Computer)
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Weight Data Sheet
Operating
Temperature STANDARD OPTIONAL
(Transducers)
-94 to +293 °F (-70 to -166 to +428 °F (-110 to
+145 °C) *) +220 °C) **)
4.3 Operating Pressure 11.6 - 145 psiA (0.8 to 10 barA)
*)
: Lower temperatures than -70 °C for short period of times.
**): Pipe Sizes: 6” – 30”.
5. Design Limits
Design Temperature
5.1 STANDARD OPTIONAL
(Transducers)
-238 to +599 °F (-150 to -238 to +662 °F (-150 to
+315 °C) *) +350 °C) *)
5.2 Design Pressure 290 psiA (20 barA)*)
*)
: Mechanical survival ratings, NOT operational survival ratings.
6. Electrical Data
6.1 Supply Voltage STANDARD OPTIONAL

Power converter from AC to
24 VDC (20 - 32 VDC) DC with Exd enclosure and
sunshade
6.2 Power Consumption 13 VA max
6.3 Input Signal Transit times: from ultrasonic transducers
Temperature & Pressure: analog 4-20 mA or
digital HART communication
STANDARD OPTIONAL
6 x analog 4-20 mA outputs
HART output Foundation Fieldbus
6.4 Output Signal
Pulse / frequency signal TCP/IP via Ethernet
RS422 / RS485, 2- or 4- SoftFlow
wire Modbus Protocol, RTU
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Weight Data Sheet
Each output channel can individually be set to one of the

following:
· Volume flowrate at reference conditions
· Volume flowrate at line conditions
· Mass flow
· Density at standard conditions
· Density at operational conditions
· Molecular weight
· Alarm High
· Alarm Low
· Temperature
· Pressure
6.5 Frequency Output 1 x Frequency outputs. fmax = 2 kHz
6.6 Pulse Output 1 x Pulse output (max 250 pulses/s)
6.7 Serial Link to DCS RS422 / RS485, 2- or 4-wire
Modbus protocol, ASCII or RTU
Foundation Fieldbus *)
6.8 1 x FF Output (4 variables)
Interface
Serial link to O&SC
6.9 **) RS485, 2- or 4-wire
Modbus protocol, RTU

*)
: disables DCS and analog 4-20 mA communication
**)
: Operator & Service Console
7. Functional Characteristics
7.1 Flow Velocity Range 0.1 - 394 ft/s (0.03 - 120 m/s)
STANDARD OPTIONAL
7.2 Accuracy
+/- 2.5% to 5% +/- 1% to 2%
7.3 Resolution 0.003 ft/s (0.0008 m/s)
Better than 1% of volume flow for velocity 0.3 - 100 m/s
7.4 Repeatability
(1 - 328 ft/s)
7.5 Turn Down Ratio 4000:1
7.6 Calibration Zero flow calibration*
Standard and actual volume flow, mass flow, totalized
Measurement standard volume flow, totalized mass flow, molecular
Parameters weight, standard density, actual density, pressure,
temperature, speed of sound, gas velocity
* Wet (flow) calibration on third-party rig for improved measurement accuracy can be offered.
8. Measuring Section
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Weight Data Sheet
Material Wetted Stainless steel 316L (Nace MR 0-175) or to customer’s

8.1
Parts specification
8.2 Ball Valves 2” 150# RF Full bore to customers’ specification
Upstream Straight 10 x ID (20 x ID: Norwegian Petroleum Directorate
8.3
Pipe Requirements regulation)
Downstream
5 x ID (8 x ID: Norwegian Petroleum Directorate
8.4 Straight Pipe
regulation)
Requirements
Transducer length:
Transducer Full Size - TFS;
8.5 Dimensions In operation: 0.71 m (2.33 ft)
Retracted: 1.03 m (3.38 ft)
Transducer Cable length: up to 167 ft (51 m)
8.6 Installation 45° angle: centre line transducers / run pipe
Transducers: 6”- 10” à pipe: 42° / 48°,
12”- 72” à pipe: 45° / 45°
Special metering / welding jigs to be used during
installation of transducer holders
9. Field Computer
9.1 Installation Ex-d/e enclosure

Parameter viewing of predefined set of process parameters
9.2 Local Display *)
9.3 Dimensions Ca. 280 x 470 x 290 mm (W x H x D)

9.4 Weight Appr. 16 kg
*)
: Predefined parameter set;
· Volume flow rate @ actual (flow) conditions
· Mass flow rate @ actual (flow) conditions
· Totalized volume flow
· Totalized mass flow
· Last 24h totalized mass flow
· Pressure
· Temperature
10. Operator Console
Single System View;

10.1 System View
detailed data view, trend log, configuration
10.2 SW upload Via integrated Service Console
10.3 Remote Operation Via RS485-TCP/IP interface or Remote Control Software
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Weight Data Sheet
11. References
N/A.
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Weight Data Sheet
3.3 Weight Data Sheet
1. Purpose ...................................................................................................... 23
2.1 Abbreviations:.......................................................................................................................... 23
2.2 Definitions: .............................................................................................................................. 23
3. Weight Data Sheet ....................................................................................... 23
3.1 Transducer Full Size (TFS) Weight Data Sheet ......................................................................... 23
4. References .................................................................................................. 23
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Weight Data Sheet
1. Purpose
This document specifies the weight of the components included in the Fluenta Flare
Gas Meter, FGM 160.
2.1 Abbreviations:
FGM 160 Fluenta Flare Gas Meter, model FGM 160
2.2 Definitions:
EEx-d/e FGM 160 in EEx-d explosion proof enclosure and connection housing in
EEx-e enclosure.
3. Weight Data Sheet

3.1 Transducer Full Size (TFS) Weight Data Sheet
Table 1 indicates the weight of an FGM 160 with up to two sensor pairs. The sensors
involved are Transducer Full Size (TFS) and the FGM 160 in an EEx-d/e housing. All
weights are listed in [kg] and [lbs].
Table 1 – Transducer Full Size and EEx-d/e housing
Weight data Unit 1 system 2 systems

[kg] lbs [kg] [lbs] [kg] [lbs]
EEx – d/e enclosure 16 35.2 16 35.2 16 35.2
Transducer FGM 160 7.25 16 14.5 32 29 63.8
Ball valve (typical) incl. bolts and

14 31 28 62 56 123
nuts
Transducer holder 5.5 12 11 24 22 48
Transducer cable 0.39 kg/m 0.25 lbs/ft
Power cable 0.20 kg/m 0.13 lbs/ft
Complete system 69.5 152.9 123 270.6
Approx. shipping weight 122 268.4 228 501.6
Note! Cables are not included in the weight of the complete system as this
depends on the specific cable length, but weight per unit length is
indicated.
4. References
N/A.
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Functional Description
4. TECHNICAL DESCRIPTION
4.1 Functional Description
4.2 Flow Calculations
4.3 Cable Descriptions
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4.1 Functional Description

1. Purpose ...................................................................................................... 26
2.1 Abbreviations:.......................................................................................................................... 26
2.2 Definitions: .............................................................................................................................. 26
3. General ....................................................................................................... 26
3.1 Reference Conditions .............................................................................................................. 26
3.2 Units of Measurement............................................................................................................. 26
3.3 Language .................................................................................................................................. 26
4. General Technical Descriptions ....................................................................... 27
4.1 Challenges Involved in Flaregas Metering ............................................................................... 27
4.2 General Description of FGM 160 ............................................................................................. 27
4.3 Detailed Explanation of the Measurement Signals ................................................................. 28
4.3.1 Continuous Wave (CW) Measurements .......................................................................... 29
4.3.2 Chirp Measurements ....................................................................................................... 29
5. Field Computer Unit ...................................................................................... 30
5.1 General .................................................................................................................................... 30
5.2 Field Computer Description ..................................................................................................... 30
5.2.1 DSP; Digital Signal Processing .......................................................................................... 31
5.2.2 AFE; Analogue Front End ................................................................................................. 31
5.2.3 P&T; Pressure & Temperature ......................................................................................... 31
5.2.4 I/O; Input/Output ............................................................................................................ 31
5.2.5 IS-Barrier; Intrinsic Safety Barrier Module ...................................................................... 31
5.3 Operating the Field Computer ................................................................................................. 32
5.3.1 Operator Console............................................................................................................. 32
5.3.2 Remote Console............................................................................................................... 32
5.4 Input Signals ............................................................................................................................ 32
5.4.1 Transit Time Input Signal ................................................................................................. 32
5.4.2 Pressure Input Signal ....................................................................................................... 32
5.4.3 Temperature Input Signal ................................................................................................ 33
5.5 Output Signals ......................................................................................................................... 33
5.5.1 Pulse/Frequency Output.................................................................................................. 33
5.5.2 Analogue 4-20mA Output Signals .................................................................................... 33
5.5.3 HART Output .................................................................................................................... 33
5.5.4 Modbus Serial Interface .................................................................................................. 34
5.5.5 Foundation Fieldbus Interface ......................................................................................... 34
6. Ultrasonic Transducers .................................................................................. 34
6.1 Transducer Full Size (TFS) ........................................................................................................ 34
6.2 Transducer Full Size, Ball Valves .............................................................................................. 34
7. References .................................................................................................. 35
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1. Purpose
This document describes the Fluenta Flare Gas meter, FGM 160. The main
components in the system are described and the measuring techniques are explained.
2.1 Abbreviations:
FGM Flare Gas Meter
2.2 Definitions:
N/A
3. General
3.1 Reference Conditions
The following reference conditions are used as a basis:
Pressure : 1.01325 bar a

Temperature : 15 °C = 288.15 K
3.2 Units of Measurement

The following units of measurements are used in the FGM 160:
Measurement SI U.S.
Length : mm in
2
Area : m ft2
Volume : m3 or Sm3 MMCF or MMSCF
Mass : kg lb
3 3
Volume flow rate : m /h or Sm /h MMCFD or MMSCFD
Mass flow rate : kg/h lb/h
3
Density : kg/m lb/ft3
Pressure (absolute) : bar a psi
Temperature : °C F
3.3 Language
The FGM 160 is supplied with English text as standard.
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4. General Technical Descriptions

4.1 Challenges Involved in Flaregas Metering
Challenges that must be overcome in order to measure flare gas are among others:
· Large velocity variations for the gas flowing in the flare pipe.
· Large pipe diameters.
· Low pressure situation at the metering point.
· Field-mounted sensor shall operate in explosive or potentially explosive areas, thus

limited power is available.
The FGM 160 is designed to operate under these difficult conditions and the capability
to do so is verified by instruments presently in operation. The ultrasonic sensors are
wetted but non-intrusive, and will thus not disturb the flowing gas. The meter has no
mechanical moving parts, which makes the instrument less exposed to wear.
The problem associated with high flow velocities is, among others, that the gas
flowing in the pipe represents a source of noise, which reduces the recognisability of
the transmitted, ultrasonic signal. Also, high gas velocities will carry the ultrasonic
pulses along the pipe, which makes it even more difficult for the sensors to
communicate.
Low pressures, large pipe diameters and limitations on the amount of electric power
that can be applied due to explosive area regulations, are all elements that increase
the difficulty in obtaining good measurements. These problems are solved by using
two different types of signals, Continuous Wave and Chirp. This measurement
technique is described further in this document.
4.2 General Description of FGM 160

The FGM 160 system consists of a Field Computer and a transducer pair. Transducers
are ultrasonic sensors mounted on the flare gas pipes, ref. Figure 1.
Figure 1 The FGM 160 system with one pair of ultrasonic sensors.
72.120.606/D Page 27 of 211

The FGM 160 measures the gas velocity by using the time of flight technique, which
means that the ultrasonic transducers communicate with each other by transmitting
and receiving ultrasonic signals.
Downstream (B)
n t21
L t12
D
q
Upstream (A)
Figure 2 Transit time measurement principle.
With reference to Figure 2, the measurement principle may be explained as follows:
Both transducers transmit and receive ultrasonic pulses and the difference in transit
time between the downstream pulse (from A to B) and the upstream pulse (from B to
A) is measured. When gas is flowing in the pipe, a pulse travelling against the stream
(upstream) will use longer time to reach the opposite transducer than a pulse
travelling with the flow (downstream). This time difference is used to calculate the
velocity of the flowing medium by the following equation:
L t -t
n= × 21 12
2 cos q t12 × t 21
where:
n = axial velocity of flowing medium without compensation for Reynolds
Number variation
L = distance between transducer tips
q = angle of intertransducer centre line to axis of pipe
t12 = transit time (sec) from Transducer (A) to Transducer (B) (downstream)
t 21 = transit time (sec) from Transducer (B) to Transducer (A) (upstream)
4.3 Detailed Explanation of the Measurement Signals

As outlined in section 4.2, the measurement principle is based on transit time
difference. This section gives a more detailed description of the signal types used to
perform the measurements. Two different signal types are used, and the combination
of these two makes the FGM 160 a unique instrument for flare gas measurement
purposes.
72.120.606/D Page 28 of 211

The two signal types used are:
CW - Continuous Wave (Signal burst)

Chirp - Variable frequency signal
4.3.1 Continuous Wave (CW) Measurements

This CW signal has a constant frequency and amplitude as illustrated in Figure 3.
Figure 3 Continuous Wave (CW) signal (burst).
This is general signal type used in ultrasonic instruments. When measuring flare gases
at high velocities, the medium in the pipe line will generate significant acoustic noise.
This acoustic noise may have equal or higher amplitude than the CW signal, which
makes detection difficult, if not impossible. This signal is therefore only suitable for
measurements at low gas flow velocities.
4.3.2 Chirp Measurements

According to section 4.3.1, CW signals are not suitable for measuring flare gases at
high velocities. A solution to this problem is to use a time varying signals instead,
called Chirps. These signals are given a unique recognizable form characterised by the
pulse duration and the varying signal frequency. Their unique form makes them
detectable through the acoustic noise induced by the flowing medium. Figure 4
illustrates a Chirp signal with varying frequency and fixed amplitude.
72.120.606/D Page 29 of 211

Figure 4 Chirp signal, with varying frequency and fixed amplitude.
Chirp signals are used in combination with CW signals for measuring flare gases at low
velocities. At higher velocities the instrument only utilizes Chirp signals.
The combination of Chirp and CW at low velocities enhances the accuracy of the FGM
160 measurements for these velocities.
5. Field Computer Unit

5.1 General
The processing of the information from the transducers and from the pressure and
temperature transmitters are performed in the FGM 160. The Field Computer controls
the transmission to and detection of signals from the transducers and performs the
critical transit time measurements. The Field Computer also performs calculations
based on the time measurement results and presents data and alarm messages.
5.2 Field Computer Description

The FGM 160 Unit, shown in Figure 5, consists of two enclosures, the EEx-d enclosure
and the EEx-e enclosure. The EEx-d enclosure contains the computer unit and all the
system electronics. The computer unit and the electronics form a stack, with defined
and distributed tasks. A distributed system will be more flexible with respect to future
expansions and modifications, as the total processing load for the system can be
divided on several modules. Thus, the danger of overloading a single CPU unit is
reduced.
The PCB stack module can be divided into five main components or units. A Local
Display has been standard for the FGM 160 since 2007, completing the PCB stack with
a total of 6 boards.
72.120.606/D Page 30 of 211

Figure 5 FGM 160 Field Computer.
5.2.1 DSP; Digital Signal Processing

The Digital Signal Processing unit is the systems master. The DSP unit generates the
measurement signals and controls the measurement sequences. It collects data from
the other module registers and performs flow calculations based on this data. All
calculated parameters are stored in defined registers and made available for the DCS
system and the Operator & Service Console through the I/O unit.
5.2.2 AFE; Analogue Front End

The Analogue Front End unit is the interface between the DSP unit and the ultrasonic
transducer sensors via the IS-Barrier unit. At the AFE unit, measurement signals are
multiplexed and switched between CW- and Chirp-signals, and upstream and
downstream direction.
5.2.3 P&T; Pressure & Temperature

The Pressure & Temperature unit collects pressure and temperature information from
external sensors via 4-20 mA current loop or HART interface. All pressure and
temperature data are stored in predefined registers available for the DSP unit. Thus,
the DSP unit can retrieve P&T parameters in a minimum of time.
5.2.4 I/O; Input/Output

The Input/Output unit is the interface between the FGM 160 in hazardous area and
equipment in safe area. At the I/O unit, 24 VDC supply voltage is converted to the
required operational voltages for the other units in the stack. Further, all signals and
communication to and from the DCS system and Operator & Service Console are
handled by this unit.
5.2.5 IS-Barrier; Intrinsic Safety Barrier Module

The Intrinsic Safety Barrier Module ensures the intrinsic safety to the ultrasonic
sensors mounted in hazardous areas. The total energy is kept within safe limits to
prevent explosions due to excessive heat. In addition, the IS-Barrier unit includes
safety barriers for the P & T transmitters. Thus, P&T transmitters with “Ex i”
certification can be interface directly to the FC I.
72.120.606/D Page 31 of 211
The EEx-e enclosure is a junction/connection box. It houses the necessary terminal

blocks and is the physical link between the FGM 160 and the transducers. All
communication wiring provided by the FGM 160 and power supply goes via this
enclosure.
An entire EEx-d solution will be available on request. The EEx-e housing is then
removed, and the terminal blocks and the FGM 160 Unit are integrated in a common
EEx-d housing.
5.3 Operating the Field Computer

5.3.1 Operator Console
Operating the FGM 160 from an Operator Console connects from the FC I via a
Modbus RS485 connection. According to the RS485 standard, the Operator Console
can be located up to 1200 meters away from the FC I. A DCS system via Modbus
RS422 or RS485 gives access to basic parameters and limited system management.
The interface is based on entering commands with corresponding values. These
commands are predefined and described in detail in the User’s Manual. The
corresponding value can either be a new parameter value or only a display value
telling the FGM 160 to display a certain parameter or result.
5.3.2 Remote Console

An option for a NetOp server is available if desirable. NetOp is a Remote Control
Software that gives access to the Operator/Service Console through a TCP/IP
connection. A NetOp server installed locally in the Service Console enables full access
to the system for operators off-site with a NetOp client if access is approved on-site.
This solution eliminates the demand for on-site Operator/Service Control since full
access and system control is available from any location.
This solution also makes it possible for Fluenta AS to remote the system, assist with
diagnostics and offer online software updates and support. Software updates for DSP,
P&T and I/O can be upgraded on-the-fly.
A RS 485 to TCP/IP converter enables Fluenta AS to assist with diagnostics and

support, but control of the system is not possible with this solution.
5.4 Input Signals

5.4.1 Transit Time Input Signal
The ultrasonic transducer pair supplies the FGM 160 with upstream and downstream
transit time measurements, ref. section 4.2. These measurements in combination with
the pressure and temperature measurements, described in section 5.4.2 and 5.4.3,
form the foundation for the FGM 160 outputs described in section 5.5.
5.4.2 Pressure Input Signal

The pressure measurement is performed close to the transducers to get the correct
pressure at the measuring point. The pressure measurement point is downstream the
transducers relative to flow measurement.
72.120.606/D Page 32 of 211

The pressure input signal is either in form of a 2-wire 4-20 mA signal or through HART
transmitter modem. The locally mounted transmitter is either powered by the 24 VDC
power supply in the FGM 160, or an external source.
5.4.3 Temperature Input Signal

The temperature probe is installed furthest away(downstream) from the measuring
point to limit the effect of potential turbulence.
The FGM 160 collects data from the temperature transmitter through 4-20 mA or
HART interface. The temperature transmitter is connected to the FGM 160 by 2 wire
configuration. The locally mounted temperature transmitter is powered in the same
manner as the pressure transmitter.
The pressure transmitter and the temperature transmitter are connected to the FGM
160 through internal barriers in the FGM 160 Field Computer. The analogue inputs are
realized as floating 20 ohm resistors, through which the loop current flows. The
common mode voltage range is within -10 to +24 volts with respect to the FGM 160’s
ground level.
5.5 Output Signals

5.5.1 Pulse/Frequency Output
The FGM 160 has 3 pulse output channels that can e.g. be configured for totalising of
mass and volume.
Two of these pulse output channels can be configured as frequency output channels
with a frequency range from 10Hz to 4 kHz. These outputs can be configured e.g. for
mass or volume flowrate.
5.5.2 Analogue 4-20mA Output Signals

The FGM 160 has six analogue 4-20 mA output channels. Each of the six output
channels can be configured to one of the following parameters:
· Standard Volume Flow rate

· Actual Volume Flow rate
· Mass Flow rate
· Density (Standard Conditions)
· Density (Actual)
· Molecular Weight
· Pressure
· Temperature
· Alarm = 4 mA (Alarm LOW)
· Alarm = 20 mA (Alarm HIGH)
Analogue outputs are disabled in FGM 160 Foundation Fieldbus configuration.
5.5.3 HART Output
72.120.606/D Page 33 of 211

The FGM 160 has one analogue output channel that can be configured as a HART
output interface. The HART output interface supports function code 0, 1 and 3. Refer
to Fluenta AS doc. no: 72.120.306 – FGM 160 HART Interface Specification, for a
detailed description of the HART interface.
5.5.4 Modbus Serial Interface

Parameters in the FGM 160 are accessible through a serial interface by using the
Modbus protocol. All or just a selected range of parameters in an array can be
accessed in a single read or write operation. Single precision floating-point
presentation is the implemented format. Some arrays contain ‘Read only’ parameters.
Others contain ‘Read / Write’ parameters.
Refer to Fluenta AS doc. no. 72.120.305 – FGM 160 Modbus Interface Specification for
a full description of the Modbus interface.
Modbus DCS communication is disabled in FGM 160 Foundation Fieldbus configuration.
5.5.5 Foundation Fieldbus Interface

Maximum 4 parameters can be predefined according to customer’s requirement. List
of parameters available for the customer can be found in Fluenta AS doc. No.
72.120.305 (all parameters available using Modbus Serial Interface are accessible
using Foundation Fieldbus output).
6. Ultrasonic Transducers
6.1 Transducer Full Size (TFS)
The ultrasonic transducers mounted onto the flare pipe are approved for operation in
Zone 0 with safety class EEx ia IIC T6. They are mounted in transducer holders that
are welded on to the flare pipe at carefully selected angles, positioned with specially
designed mounting jigs.
A piezo-electric crystal is mounted inside the titanium housing at the front of the
transducer. When the crystal is subjected to an alternating electrical signal, it vibrates
with the same frequency as the electrical signal. The crystal is attached to the front
membrane of the titanium housing and this membrane vibrates with the crystal. The
membrane movement generates the ultrasonic signals. When a transducer receives
ultrasonic signals, the membrane vibrates and the crystal transfers this movement
into an electrical signal.
Both transducers in a pair operate as transmitter and receiver. At the transmitting

transducer an electrical frequency signal is converted to an ultrasonic pulse. At the
receiving transducer, the signal is converted back to an electrical frequency signal,
enabling the system to determine the time of travel for the ultrasonic pulse using
cross correlation. The measured transit times are used to calculate the axial gas flow
velocity and volume flow rate in the pipeline.
6.2 Transducer Full Size, Ball Valves

Ball valves are mounted between the full size transducer and holder to enable
installation and retraction of the transducers during normal process operation. The
pressure sealing is established using a tube fitting solution which after initial
72.120.606/D Page 34 of 211
installation ensures that the transducer position remains constant even after the
transducer have been taken out for servicing.
7. References
N/A
72.120.606/D Page 35 of 211

Installation & Hook-Up Instructions
4.2 Flow Calculations

1. Purpose ...................................................................................................... 37
2.1 Abbreviations: ..........................................................................................................................37
2.2 Definitions: ...............................................................................................................................37
3. Flow Calculations ......................................................................................... 37
3.1 Axial Gas Flow Velocity Calculation ..........................................................................................37
3.2 Reynold’s Number Calculation .................................................................................................38
3.3 Correction Factor Calculation ...................................................................................................38
3.4 Average Axial Gas Flow Velocity Calculation ............................................................................39
3.5 Volume Flowrate Calculation ...................................................................................................39
3.6 Mass Flowrate Calculation .......................................................................................................39
3.7 Density Calculation ...................................................................................................................40
4. References .................................................................................................. 41
72.120.606/D Page 36 of 211

1. Purpose
This document lists the fundamental formulas and data used in the Fluenta Flare Gas
Meter, FGM 160, to calculate flow velocity and volumetric and mass flow rate.
2.1 Abbreviations:
FGM Flare Gas Meter
Additional abbreviations used in this chapter are for simplicity explained in same
section where used.
2.2 Definitions:
Definitions used in this chapter are for simplicity given in same section where used.
3. Flow Calculations
Formulas and data used in the FGM 160 calculations are given in the following
sections.
Flow calculations performed by the FGM 160 can be derived from Figure 6.
2 (B)
n t21
L t12
D
q
1 (A)
Figure 6 Sensor alignment and parameters of importance for the flow calculations.
3.1 Axial Gas Flow Velocity Calculation

L t -t
n= × 21 12
2 cos q t12 × t21
Equation 1 Axial gas flow velocity calculation.
72.120.606/D Page 37 of 211

where:
n = axial velocity [m/s] of flowing medium without compensation for

Reynold’s number variations
L = distance between transducers
q = angle of inter-transducer center line to axis of the pipe
t12 = transit time (sec) from Transducer 1 (A) to Transducer 2 (B)
(Downstream)
t 21 = transit time (sec) from Transducer 2 (B) to Transducer 1 (A)
(Upstream)
3.2 Reynold’s Number Calculation
v × D × P × T0 × Z0
Re =
Kin.Visc.× P0 × T × Z
Equation 2 Reynolds number calculation.
where:
Re = Reynolds number
P = Measured pressure in Bar A
P0 = 1.01325 barA (reference conditions)
Kin.Visc. = Kinematic Viscosity (See value below)
T0 = 288.15 K = 15 °C (reference conditions)
T = Measured temperature in Kelvin
Z0 = Compressibility factor at reference conditions
Z = Compressibility factor at operating conditions
Kin.Visc. , Z 0 and Z are operator entries (default);

Kin.Visc. = 15 ´ 10 -6 m2/s
Z0 = 1.0 (default)
Z = 1.0 (default)
3.3 Correction Factor Calculation
k = f (Re)
Equation 3 Flow profile correction factor based on Reynolds number.
where:
k = Correction factor used as compensation for flow profile variations,

derived as Reynolds number.
k is typical in range: 0.89 – 0.96

72.120.606/D Page 38 of 211
3.4 Average Axial Gas Flow Velocity Calculation
_
v = k ×v
Equation 4 Average axial gas flow velocity calculation.
where:
v = Average axial velocity [m/s] of flowing medium compensated for

Reynolds number (flow profile) variations.
3.5 Volume Flowrate Calculation
P T0 Z0
QV = A × v × × × × 3600
P0 T Z
Equation 5 Volumetric flow rate calculation, at reference conditions.
where:
Qv = Volume flow rate at reference conditions [Sm3/h]

A = Cross-sectional area of pipe [m2]
3.6 Mass Flow rate Calculation
Qm = QV × (1 M ) × rb
Equation 6 Mass flow rate calculation based on volumetric flow rate at referenced
conditions.
where:
rb = Calculated gas density [kg/m3]
P T0 Z 0
M = × ×
P0 T Z
Qm expressed related to gas flow velocity:
72.120.606/D Page 39 of 211

Qm = A × v × r b × 3600
Equation 7 Mass flow rate calculation based on average axial gas flow velocity.
3.7 Density Calculation

The FGM 160 calculates the gas density and molecular weight using process
information obtained through ultrasonic time measurement, measured temperature
and pressure in actual conditions. Density can be calculated using one of two models:
General Density Model (GDM), which is a blind model with no prior knowledge of gas
composition, a or more accurate Enhanced Density Model (EDM), where gas
composition can be used in FGM density and molecular weight calculation functions.
This can reduce the applicable taxation costs thanks to lower mass flow when purging
the flare stack with nitrogen.
General Density Model:

The General Density Model (GDM) is based on the relationship between known
properties of hydrocarbon gases at low pressure, gas density, and molecular weight.
Density and molecular weight is calculated using measured velocity of sound (VoS),
pressure (P), temperature (T) and Reynolds number (gas constant = 8.31432 J/mol *
K). The GDM is a general, “blind” model, with no previous knowledge on the gas
composition of a specific installation.
Input:
Velocity of Sound (VoS) Calculated based on ultrasonic transit time
measurements.
Pressure (P) Measured with the Pressure Transmitter.
Temperature (T) Measured with the Temperature Transmitter.
Output:
Gas Density
Molecular Weight
Mass Flow rate
Enhanced Density Model:
For more accurate density calculations, Enhanced Density Model can be used. In this
mode it is possible to enter the gas composition into the FGM configuration. It can
also be done via DCS. Second option allows keeping a more up-to-date gas
composition data in the FGM’s memory.
While using EDM, it is automatically chosen from two available scenarios – flaring
mode or purging mode. The switch is made depending on flow velocity. The switching
point is set by an operator through O&SC or DCS modbus. Flaring mode is default for
calculating mass being flared (high flow velocity) and purging mode (low flow
velocity) and takes into consideration the amount of nitrogen used to purge the flare
stack. In purging mode, less mass is being totalized because the amount of nitrogen
is not being taken into account while it is present in the volume flow.
72.120.606/D Page 40 of 211

Input:
Velocity of Sound (VoS) Calculated based on ultrasonic transit time
measurements.
Pressure (P) Measured by Pressure Transmitter.
Temperature (T) Measured by Temperature Transmitter.
Normalized Gas Composition Inserted via operator console or through DCS
Output:
Gas Density
Molecular Weight
Mass Flow rate
Defined gas composition can be entered via Modbus into registers presented below:
Register no. Value
1140 Molar fraction of C1, Methane. [%]
1141 Molar fraction of C2, Ethane. [%]
1142 Molar fraction of C3, Propane. [%]
1143 Molar fraction of C4, Butane. [%]
1144 Molar fraction of C5, Pentane. [%]
1145 Molar fraction of C6 and higher order hydrocarbons, Hexane ->. [%]
1146 Molar fraction of N2, Nitrogen. [%]
1147 Molar fraction of Co2, Carbon Dioxide. [%]
To turn on selected density model service operator need to change 10107 registers
through O&SC. For other option while choosing EDM please refer table below.
Register no. Value Description
0 Old model(FGM130)
10107 1 Enhanced model
2 Enhanced model, default composition
Velocity limit for change from purging to flaring mode in
10108 m/s
new enhanced density model (default 2 m/s)
Velocity limit for change from flaring to purging mode in
10109 m/s
new enhanced density model (default 1 m/s)
Gas density model used at last calculation (current register
values)
Read- 0: General gas density model (old FGM 130 model)
1025
only 1: Improved gas density model, Flaring scenario
2: Improved gas density model, Purging scenario (N2
fraction is calculated in addition to density and mol.weight)
Nitrogen fraction [%]. Only valid in purging scenario,
Read- otherwise value is 0.
1026
only Error conditions (underflow/overflow) are indicated by
values: -0.001 and 100.001.
4. References
N/A
72.120.606/D Page 41 of 211

4.3 Cable Description

1. Purpose ...................................................................................................... 42
2.1 Abbreviations: ..........................................................................................................................42
2.2 Definitions: ...............................................................................................................................42
3. Field Computer Power Cable Specification ....................................................... 43
3.1 General Properties ...................................................................................................................43
3.2 Cable Construction ...................................................................................................................43
3.3 Range and Dimensions RFOU (i) ...............................................................................................44
3.4 Technical Data ..........................................................................................................................44
3.5 Electrical Characteristics...........................................................................................................44
3.6 Fire Tests Certifications ............................................................................................................44
3.7 Gland Recommendation for Flame Retardant Cables ..............................................................44
4. Transducer Cable Specification....................................................................... 44
4.1 General Properties ...................................................................................................................45
4.2 Cable Construction ...................................................................................................................45
4.3 Range and Dimensions RFOU(c) ...............................................................................................45
4.4 Technical Data ..........................................................................................................................46
4.5 Electrical Characteristics...........................................................................................................46
4.6 Standards Applied ....................................................................................................................46
5. References .................................................................................................. 46
1. Purpose
The following sections describe the most commonly used cables in Fluenta Flare Gas
Meter, FGM 160 system.
2.1 Abbreviations:
FGM 160 Fluenta Flare Gas Meter, model FGM 160
2.2 Definitions:
N/A
72.120.606/D Page 42 of 211

3. Field Computer Power Cable Specification

The cable presented below is the most commonly used cable within the FGM 160
system. The cable utilized is a RFOU(i). Other alternatives are available on request.
3.1 General Properties

· Flame retardant cable with individual screen.
· Design guidelines according to IEC 60092-3.
· Fixed installation for instrumentation, communication, control and alarm systems
in both EX- and safe areas.
· Meets the mud resistant requirements in NEK606.
3.2 Cable Construction
1 2 3 4 5 6 7 8 9
11 21 3
Code
Letter
1. Conductor Tinned, annealed, stranded copper.
2. Insulation R EP-rubber
3. Twinning Color coded cores twisted together and wrapped
with polyester tape.
4. PETP-tape
5. Bedding F Flame retardant halogen-free thermoset
compound.
6. PETP-tape
7. Armor O Tinned copper wire braid.
8. PETP-tape
9. Outer sheath U Flame retardant halogen-free and mud resistant
thermoset compound.
72.120.606/D Page 43 of 211

3.3 Range and Dimensions RFOU (i)
No. of Conductor Insulatio Diameter Diameter Weight of

pairs/triples diameter n over overall cable
and conductor approx. thickness bedding
area
mm Ø mm Ø mm Ø mm Ø kg/km
mm²
1 pair 0,75 1,10 0,80 9,0 ±1,0 11,5 ±1,0 200

2 pair 0,75 1,10 0,80 11,5 ±1,0 15,0 ±1,0 341
4 pair 0,75 1,10 0,80 13,5 ±1,0 17,5 ±1,0 500
7 pair 0,75 1,10 0,80 16,5 ±1,0 20,5 ±1,5 706
8 pair 0,75 1,10 0,80 19,0 ±1,0 23,0±1,5 847
12 pair 0,75 1,10 0,80 21,5 ±1,5 26,0 ±1,5 1150
16 pair 0,75 1,10 0,80 24,0 ±1,5 29,0 ±1,5 1378
19 pair 0,75 1,10 0,80 25,0 ±1,5 29,5 ±1,5 1543
24 pair 0,75 1,10 0,80 29,5 ±1,5 35,0 ±2,0 1984
32 pair 0,75 1,10 0,80 33,0 ±2,0 39,0 ±2,0 2540
3.4 Technical Data

Operating voltage 250 V
Max. operating conductor temperature 85 °C
3.5 Electrical Characteristics

Capacitance approx. 90 nF/km
Inductance approx. 0.75 mH/km
Resistance at 20°C max. 24.8 Ohm/km
3.6 Fire Tests Certifications

Flame retardance IEC 60332-3/A
Halogen-free properties IEC 60754-1,2
Flame retardance IEEE 45/383
3.7 Gland Recommendation for Flame Retardant Cables

Ex (d) - Glands with seal on both inner and outer sheath
Ex (e) - Glands with seal on outer sheath only
4. Transducer Cable Specification

The coupling between the Field Computer (FGM 160) and the transducers is provided
by a RFOU(c) cable.
72.120.606/D Page 44 of 211

4.1 General Properties

· Flame retardant cable.
· Design guidelines according to IEC 60092-376(2003-05).
· Fixed installation for instrumentation, communication, control and alarm systems
in both EX- and safe areas.
· Meets the mud resistant requirements in NEK TS 606:2009.
4.2 Cable Construction
Code
Letter
Conductor Tinned, annealed, stranded circular copper.
Insulation R EP-rubber
Twinning Color coded cores twisted together and wrapped
with polyester tape.
PET-tape
Inner covering F Flame retardant halogen-free thermoset
compound.
PET-tape
Armor O Tinned annealed copper wire braid.
PET-tape
Outer sheath U Flame retardant halogen-free and mud resistant
thermoset compound.
4.3 Range and Dimensions RFOU(c)

area
mm²
72.120.606/D Page 45 of 211


area
mm²
4 pair 0,75 1,10 0,60 11.5 ±0.8 15 ±0.8 390
4.4 Technical Data

Operating voltage 250 V
Max. operating conductor temperature 90 °C
Min. installation temperature -20 °C
Min. bending radius free installation 8xD
Min. bending radius fixed installation 6xD
4.5 Electrical Characteristics

Capacitance approx. 100 nF/km
Inductance approx. 0.67 mH/km
Resistance at 20°C max. 26.3 Ohm/km
4.6 Standards Applied
Design IEC 60092-376 (2003-05)

Conductor IEC 60228 class 2
Insulation IEC 60092-351
Sheath IEC 60092-359
Flame Retardant IEC 60332-1
Flame Retardant IEC 60332-3-22
Halogen Free IEC 60754-1,2
Low Smoke IEC 61034-1,2
5. References
NA
72.120.606/D Page 46 of 211

5. HANDLING, INSTALLATION AND STORAGE
5.1 Preservation, Packing, Unpacking and Storage Procedure
5.2 Installation & Hook-Up Instructions
5.3 Hazardous Area Installation Guidelines
72.120.606/D Page 47 of 211

5.1 Preservation, Packing, Unpacking and Storage

Procedure
1. Purpose ...................................................................................................... 49
2.1 Abbreviations: ..........................................................................................................................49
2.2 Definitions: ...............................................................................................................................49
3. General ....................................................................................................... 49
4. Preservation ................................................................................................ 49
4.1 General .....................................................................................................................................49
4.2 Field Equipment........................................................................................................................49
4.3 Control Room/Local Instrumentation Room Equipment .........................................................49
5. Marking ...................................................................................................... 50
6. Packing and Dispatch.................................................................................... 50
7. Unpacking ................................................................................................... 51
8. Inspection ................................................................................................... 51
9. Storage and Handling ................................................................................... 51
10. References .................................................................................................. 52
72.120.606/D Page 48 of 211

1. Purpose
The purpose of this procedure is to describe Fluenta AS’s preparation for shipment
and transport to ensure that the equipment will be correctly treated from the time of
leaving Fluenta AS’s works, throughout any transport period, until it has reached its
final destination. Details on unpacking, inspection and storage procedures are also
given.
2.1 Abbreviations:
FGM Flare Gas Meter
2.2 Definitions:
N/A
3. General
All Fluenta Flare Gas Meter (FGM 160), produced and supplied by Fluenta, will be
preserved, packed, marked and shipped according to this procedure.
4. Preservation
All items will be free of dirt, oil, grease and other contaminants before preservation
and packing commences.
4.1 General
The following describes how Fluenta AS will preserve the equipment supplied to the
customers. The equipment will be preserved at all stages from leaving Fluenta AS’s
works, until it is finally placed in service.
4.2 Field Equipment

· The FGM 160 Field Computer will be shipped in the FGM 160 Field Computer
transportation box.
· All carbon steel machined/unprotected surfaces will be protected with Tectyl 506
protection oil or similar.
· Flanges will be protected using plastic cover or plywood.
· Ultrasonic transducers will have extra protection to prevent any damage to the
sensor head.
4.3 Control Room/Local Instrumentation Room Equipment

All equipment will be protected by bubble plastic or similar and packed in wooden
cases.
Tags stating the number of desiccants used will be attached to each package
72.120.606/D Page 49 of 211

5. Marking
All items will be marked with labels showing tag numbers and if necessary,
description.
6. Packing and Dispatch

The instrument items will be packed separately in wooden cases. The cases are
cushioned for protection and all cases will be filled with foam pellets or creased paper.
All packages will be marked with the relevant handling instructions, unpacking
instructions and shipping marks.
The following shipment marks will be used:
P.O. No. : <XXX>

MMT No. : <XXX>
Item : <XXX>
Supplier : <XXX>
Pack. No. : <XXX> of <XXX>
Size : <XXX>
Gross : <XXX> kg
Country of
: Norway
origin
The packing list (one for each package) will contain the following information:
- P.O. No:
- MMT No.
- Name of equipment/material.
- Item, tag or code no.
- Quantity and description of goods.
- Size and Gross weight.
- Indication complete or partial delivery.
- Point of delivery.
- Origin of goods.
- HS Number.
- Shipping marks.
The shipping documents will be located as follows:
Inside each package:
- Preservation, packing, unpacking and storage procedure (this document).
72.120.606/D Page 50 of 211

Outside each package in a waterproof envelope:
- 1 Original of each packing list.
With carrier accompanying delivery:
- 1 Original of packing list.

- 2 Originals of Commercial/Proforma Invoice.
- Additional Documentation as Material Certificates and Certificate of Origin.
- Airway bill/bill of loading.
7. Unpacking
Initial preservation has been carried out on the equipment before leaving Fluenta AS.
Due to the delicate nature of the equipment, great care should be undertaken when
handling both unopened and opened crates.
The receiver should check that all items have been received according packing lists.
All plastic film and other cover materials should be removed before the equipment is
taken into use. Make sure that all "Cortec" have been removed before start-up.
8. Inspection
The equipment shall be inspected for damage and cleanliness at receipt at
construction site. Any damage shall be reported without undue delay to the project
and the supplier. No repair work should be attempted without prior inspection and
approval from the supplier.
9. Storage and Handling

If the equipment is going to be stored before installation and commissioning the
following actions should be carried out:
· Replace all corrosion inhibitors (Cortec or similar).
· To be stored indoor.
· The equipment is preserved for 12 months storage. The preservation status should
be inspected and if necessary preservation maintenance should be carried out. The
equipment should be inspected every 6 weeks.
· The equipment should be stored under the following conditions:
Temperature: + 15 °C to + 30 °C
Relative Humidity: < 45 %
72.120.606/D Page 51 of 211

The package contains DELICATE INSTRUMENTS and must be

HANDLED WITH GREATEST CARE.
The items should be stored in their original packing until they arrive at the final
destination.
10. References
N/A
72.120.606/D Page 52 of 211

5.2 Installation & Hook-Up Instructions

1. Purpose ...................................................................................................... 54
2. Abbreviations / Definitions ............................................................................ 54
2.1 Abbreviations ...........................................................................................................................54
2.2 Definitions ................................................................................................................................54
3. General ....................................................................................................... 55
4. Unpacking ................................................................................................... 55
4.1 Inspection of Goods..................................................................................................................55
4.2 Ex-Classification Marking..........................................................................................................55
4.3 Equipment Information ............................................................................................................56
4.4 Manufacturer Information .......................................................................................................56
5. Transducer/Probe Installation ........................................................................ 56
5.1 Installation of Transducer Holders ...........................................................................................56
5.1.1 Space Requirements ........................................................................................................ 56
5.1.1.1 Space Requirements for the Transducer Full Size, TFS ................................................ 58
5.2 Mounting the Transducer Holders ...........................................................................................60
5.2.1 Orientation ...................................................................................................................... 60
5.2.1.1 Horizontal Flare Pipe .................................................................................................... 60
5.2.1.2 Vertical Flare Pipe......................................................................................................... 61
5.2.2 Cold Tapping .................................................................................................................... 62
5.2.3 Using the Sighting Tool .................................................................................................... 66
5.2.4 Hot Tapping Transducers Full Size, TFS ........................................................................... 68
5.3 Mounting the Ultrasonic Transducers ......................................................................................68
5.3.1 Determining the Correct Position for the Transducers ................................................... 68
5.3.2 Edge Flush Transducer Mounting .................................................................................... 69
5.3.2.1 Setting the correct insertion depth .............................................................................. 69
5.3.2.2 45° installations ............................................................................................................ 71
5.3.2.3 48°/42° installations ..................................................................................................... 71
5.3.3 Insertion of the Transducer Full Size (TFS) ...................................................................... 72
6. Field Computer Installation ............................................................................ 72
6.1 The Field Computer Mounting Brackets...................................................................................72
6.2 Electrical Wiring........................................................................................................................74
6.2.1 Cable Preparations .......................................................................................................... 75
6.2.2 Power Cable ..................................................................................................................... 75
6.2.3 Ultrasonic Transducer Cables .......................................................................................... 75
6.2.4 Connecting the Pressure and Temperature Transmitters ............................................... 77
6.2.5 Control Room and Data Cables ....................................................................................... 79
6.2.5.1 DCS Port, Modbus ........................................................................................................ 80
6.2.5.2 Foundation Fieldbus Output ........................................................................................ 80
6.2.5.3 Service Port .................................................................................................................. 80
6.2.5.4 Current Loop Outputs (4-20mA) .................................................................................. 80
72.120.606/D Page 53 of 211

6.2.5.4.1 Active Output Configuration (Default Configuration) ........................................... 81

6.2.5.4.2 Passive Output Configuration ............................................................................... 83
6.2.5.4.3 Current Loop Outputs Details................................................................................ 83
6.2.5.4.4 Load / Loop Voltage Limitations............................................................................ 84
6.2.5.4.5 Restrictions of the Current Loop Outputs ............................................................. 85
6.2.5.5 HART Output ................................................................................................................ 87
6.2.5.6 Pulse/Frequency/Level Output .................................................................................... 87
6.2.5.6.1 Voltage / Current Limitations ................................................................................ 87
6.3 Upgrading from the FGM 130 ..................................................................................................89
7. References .................................................................................................. 91
8. Space Requirements for the TFS .................................................................... 92
1. Purpose
The purpose of this procedure is to provide a traceable point-by-point installation
guideline for the Fluenta Flare Gas meter, Field Computer (FGM 160) system. This
document provides details on the different options that are available to the FGM 160
system, the installation of the base system, and the optional configurations. The
optional configurations include the two types of transducer, possible upgrade from
previous Fluenta Flare Gas Meters, and the different interfaces available from the Flow
Computer to the Plant Control System. The procedure also provides a means to
establish an “Installation and Hook-Up Record” to document the installation.
2. Abbreviations / Definitions
2.1 Abbreviations
FGM Flare Gas Meter

2.2 Definitions
Metering Spool Section – A section of pipe that has the transducer, pressure, and
temperature holders already mounted.
Cold Tapping – Mounting the transducer, pressure, and temperature

holders on a section of the flare pipe which has been shut
off from the flare system.
Hot Tapping – Mounting the transducer, pressure, and temperature

holders on a section of the flare pipe which is an active
part of the flare system.
72.120.606/D Page 54 of 211

Center flush – The center of the tip of the transducer is flush with the
inner wall of the pipe.
Edge-Flush – The part of the transducer tip that is inserted furthest into
the transducer holder/ball valve, is flush with the inner wall
of the pipe
Insertion depth – The distance from the tip of the transducer to the raised
part of the transducer flange.
3. General
The FGM 160 system supplied from Fluenta is designed to work with no major
preparation. Due to the complexity and the required accuracy of the measurements it
is mandatory to obtain a very high degree of precision and care during all phases of
the installation.
This procedure includes the required steps from unpacking to commissioning. After
unpacking and inspection of the received goods has been carried out, the system
should be ready for installation. The description of the installation of the system is
divided in subsections as follows:
• Transducer/ Probe installation.

• FGM 160 Field Computer installation.
Note that warranty for the transducers only applies if certified personnel install the transducers.
Certified personnel include Fluenta service engineers, service engineers of our agents who have
received proper training and operators who have attended and completed Fluenta’s 2-day
Operators Training Course.
4. Unpacking
4.1 Inspection of Goods
Installation of the equipment supplied by Fluenta must never occur without the
inspection of the supplied goods carried out first. This should be performed according
to the instructions and tasks described in:
FGM 160 Preservation, Packing, Unpacking and Storage Procedure[1].
The important issue is to verify the goods with the packing list and inspect for
damages caused by transportation. Save packing material for storing and reshipping
of the equipment, if required.
4.2 Ex-Classification Marking

Make sure that the FGM 160 is certified for the area and hazardous zone it is intended
to be installed in. The Ex-Classification marking of the equipment is described in:
FGM 160 – Hazardous Area Installation Guidelines [2].
72.120.606/D Page 55 of 211

4.3 Equipment Information

The FGM 160 requires +24 VDC power supply (nominal). If 24 VDC is not available,
an optional 110-230 VAC/24 VDC converter can be supplied by Fluenta.
For more detailed equipment information and equipment ratings, please refer to: FGM
160 – Hazardous Area Installation Guidelines[1].
4.4 Manufacturer Information
The FGM 160 Flare Gas Meter is manufactured by Fluenta AS:
Visiting address: Telephone/Fax:

Sandbrekkeveien 85 Telephone: +47 55 29 38 85
Nesttun, Bergen Fax: +47 55 13 21 60
Norway
Mail address: E-mail addresses:

P. O. Box 115, Midtun Sales: sales@fluenta.com
N-5828 Bergen Support: support@fluenta.com
Norway
5. Transducer/Probe Installation
5.1 Installation of Transducer Holders
There are three alternatives for mounting the transducer holders. The first is using a
metering spool piece that have the transducer, pressure, and temperature holders
already installed at a mechanical workshop. The second is what is referred to as
“Cold Tapping”, where the holders are installed on a section of pipe that is shut off
from the flare system. The third option is what is referred to as “Hot Tapping”, where
the holders are mounted onto a flare pipe that is active. The metering spool piece is
assembled in a mechanical workshop, and “Cold Tapping” and “Hot Tapping” are done
by welders under the supervision of Fluenta personnel.
5.1.1 Space Requirements

The space requirements around the pipe vary for transducer models and pipe
diameters. Those will be covered in the following sections. The transducers must be
mounted, regardless of the pipe diameter or transducer model, on a straight section
of pipe. The length of this straight section must be at least 15 times the diameter of
the pipe. The nearest upstream disturbance must be at least 10 times the diameter
of the pipe away from the center of the metering section, and the nearest
downstream disturbance must be at least 5 times the diameter of the pipe long.
These distances are illustrated in Figure 7. For installations that cannot meet these
requirements Fluenta should be contacted as this may have an effect on the
measurement uncertainty. As this product is a fiscal measurement system this effect
should be evaluated.
72.120.606/D Page 56 of 211

Figure 7: Fluenta’s minimum straight upstream and downstream distances to

disturbances.
72.120.606/D Page 57 of 211

5.1.1.1 Space Requirements for the Transducer Full Size, TFS

There are two different space requirements for the TFS installation. This is due to the
fact that for pipes with a diameter 10” and less, the mounting angle for the upstream
holder (U) is 48°, and for the downstream holder (D) the angle is 42°. Pipes with
diameters from 12” to 72” have a mounting angle of 45° for both. Table 2 shows the
distances required and Appendix I has a schematic of the installation for both sets of
diameters. Note that the Perpendicular Distance is the distance that the mounted
transducer assembly protrudes from the side of the pipe, and the Length is the length
of the assembly without regard to the pipe.
Table 2: The space Requirements for Transducer Full Size, TFS.
Pipe Size
6” – 10” 12” – 72”
Perpendicular Distance
Operational upstream perpendicular distance 525 mm 500 mm
Operational downstream perpendicular distance 475 mm 500 mm
Retracted upstream perpendicular distance 770 mm 730 mm
Retracted downstream perpendicular distance 690 mm 730 mm
Length
Operational 700 mm 700 mm
Retracted 1,030 mm 1,030 mm
72.120.606/D Page 58 of 211

Space Requirements for the Temperature and Pressure Transmitters

The pressure and temperature transmitters must be mounted no closer than 2D
downstream of path between the transducers (this does not apply to certain pre
fabricated spool pieces) and no longer away than 1000mm. The temperature
transmitter’s intrusive design requires that it be mounted as the furthermost
transmitter. These transmitters should be mounted on top of pipe if the pipe is
horizontality oriented or at a 90° angle to the transducers if the pipe is vertically
oriented. These positions are chosen due to good engineering practice, with a more
practical motive. This is due to the possibility that there is liquid
in the pipe, and mounting on the top of the pipe reduces the chance that they will be
harmed by an accumulation of liquid. Figure 8 illustrates the minimum distance and
orientation of the pressure and temperature transmitters.
Figure 8: Distance requirements for the pressure and temperature transmitters.
72.120.606/D Page 59 of 211

5.2 Mounting the Transducer Holders

There are three ways to mount the transducer holders. The first is by mounting a
Spool piece which is a pre-fabricated pipe with all of the holders (transducer,
pressure, and temperature) already mounted. This pre-fabricated spool piece is
inserted into the existing flare pipe system. The second option is to perform what is
referred to as Cold Tapping which means that the transducer holders are mounted
directly onto a flare pipe which has been temporarily removed or cut off from the flare
system. The last option is what is referred to as Hot Tapping which means that the
transducer holders are mounted directly onto a pipe that is being used by the flare
system. Due to the dangerous nature of this option, it is performed by a third party
with a specialty in this area.
5.2.1 Orientation
5.2.1.1 Horizontal Flare Pipe

The optimal orientation of the transducers on the flare pipe depends on whether the
flare pipe is horizontal, vertical, or inclined at a certain angle. If the transducer
holders are to be installed on a horizontal section of the flare line, the transducers
should be horizontally oriented as shown left in Figure 9. The reason for this is that
there may be fluid accumulation in the flare pipe, and if the transducers are
orientated any other way than horizontal, fluids might accumulate in the lower
transducer holder. This must then be drained to ensure the functionality of the
meter.
Figure 9: The preferred and non-preferred orientation for horizontal pipe

installation.
72.120.606/D Page 60 of 211

5.2.1.2 Vertical Flare Pipe

The transducer holders may also be mounted on a vertical section of flare pipe. The
orientation of the transducer holders in this case does not matter, as the possibility of
fluid filling the upstream transducer holder is the same regardless of the orientation.
In this case the transducer holders may be mounted in a position that suits space and
access requirements. If this is the orientation that is chosen then the upstream
transducer holder must be periodically checked for liquid accumulation and if
necessary emptied. Figure 10 shows the transducer holder orientations for a vertical
pipe. A continuous drain system may be installed by leading the fluids back into the
pipeline at a lower point of the flare stack.
Figure 10: Vertical flare boom with the transducer holders and transducers installed.
The orientation of the transducers is irrelevant for installation on a vertical
pipe run.
72.120.606/D Page 61 of 211

5.2.2 Cold Tapping

Installation of transducer holders must always be supervised by trained Fluenta
personnel, or personnel specially trained by Fluenta. Before installing the transducer
holders on the pipe, the correct placement of the spot marks must be ensured. There
are numerous ways this can be done.
First we need to look at

where the spot marks are D
Spot B
supposed to be placed.
Looking at Figure 11,
note that the horizontal
distance between spot A D
and spot B is the same as
the outer diameter of the 45° Flow Direction
pipe (applies only to 45° Spot A
installations).
The first thing to do is to

Figure 11
find the centerlines on
the pipe. Note that the ˝ D
centerlines are exactly
opposite each other on
the pipe, ref. Figure 12.
Always ensure that the
centerlines are placed
accurately by measuring
the distance between
them, both on the upper
and lower circumference.
The measured lengths Figure 12 Figure 13
should be the same.
If the pipe is horizontal, use the Curv-O- Spot

Mark contour marker to find the centerlines
on each side of the pipe, ref. Figure 13.
Remember to turn the contour marker and
set a second spot, to avoid problems in
regards to misalignment of the grade scale.
If the pipe is vertical or inclined at a certain 45° center angle

angle, other means of finding the to the pipe run.
centerlines must be applied. Confer with
the pipe fitter or welder, as they usually
have the tools and experience needed to
help you. Spot
Fluenta recommends using the special Figure 14: Marking jig used for positioning
marking jig, ref. Figure 14. of the transducer holders.
Adjust the marking-jig to fit the pipe-
diameter. Clamp it to the pipe and mark the centre-position for both transducer
holders. If no marking jig is available, other means of finding and marking the spots
72.120.606/D Page 62 of 211

must be used. We will describe two methods, but there are numerous ways this can
be done.
One proven method is to use a

marking band. After the
centerlines are marked and their
position verified, use the labeling
band to mark a line round the
pipe, placed at the first spot (spot
A), ref. Figure 15. Then, on the Spot A
other side of the pipe, measure
the distance to the second spot
(spot B). It is also a good idea to
mark another line around the
pipe at spot B, as this will help
Figure 15: Marking a line around the pipe using a
when placing transducer holder
marking band
B.
A second and just as good a method D

is to use a paper, the width of the
diameter of the pipe and length
equal to circumference. Attach the Paper
paper to the pipe and verify that the D
ends meet exactly. Take the paper
off the pipe and fold it in two. Mark Spot A
the fold, and reattach the paper to
the pipe. Spot A will then be were
the paper ends meet and spot B will
be where you marked the fold on the
other side of the pipe. See Figure 16
Figure 16: Attach the paper around the pipe
and Figure 17.
Spot B
Spot A D
πD
Figure 17: Fold the paper in two. Mark the fold. This will give you spot B.
72.120.606/D Page 63 of 211

Remove the marking-jig and clamp the welding-jig to the pipe and mount the
transducer holder. Mark the hole for the sensors on the pipe wall following the inside
rim of the transducer holder when they are mounted in the welding-jig. Repeat for
the other transducer holder. The holes can now be cut following the marked line on
the pipe-wall. Sharp edges and burrs must be avoided. A hole with smooth edges is
required. Do not make the hole to small, follow the inside rim.
After the holes are made, ensure that the inner edges are grinded to be smooth, and
beveled the correct way. Ref. Figure 18. Before the welding starts, the groove angle
must be grinded on the holders. Normally the holders must be taken off the welding-
jigs for grinding/adjustment to get the right opening and joint, ref. Figure 19.
Adjust the gap between pipe

and transducer holder until it
is correct. This is done to
get a satisfactory welding
connection. Usually the
spacing will be between
2mm and 4mm, depending
on the welder’s preference.
Note that as you raise the
transducer holder from the
pipe, it must be moved
backwards with the same
amount (applies only to 45º Figure 18 Figure 19
installations), see Figure 20.
When the transducer holders are

grinded and the holes have been
made, get the welding-jig in the
right position and connect the
transducer holder. The transducer
holder can now be tacked to the
pipe. Usually the welder will use
three or four tacks. Ensure that
there is enough space to insert the
transducer. Use the sighting tool
to verify this. The tool should be
able to be inserted without any
friction or obstructions.
The next step is to mount the

second transducer holder. Repeat
the procedure, but to verify the Figure 20: Note that as you raise the transducer
exact location/position, you must holder, you must also move it backwards to keep
use the special measuring/view the centering correct.
tool.
It is assumed that the buyers welding procedure is approved before the work starts
and that the welding is performed by certified welders.
When correct alignment of both transducer holders are ensured (see section
5.25.2.3), the welder can weld and fill out both transducer holders. Be aware that as
72.120.606/D Page 64 of 211

the welding progresses, the transducer holders can be pulled off their angles by the
welding process. Therefore it is necessary to pay close attention during the welding,
regularly checking the angles with the digital electronic level.
Figure 21: Welding jig and transducer Figure 22: Transducer holder welded to
holder. the pipe.
This job needs a skilled welder as precision and accuracy is demanded to get the
transducer holders welded into their right positions. The transducer holders are
welded onto the pipe according to the buyers welding procedure. Next step will be
NDT and final approval of the welding. The welding-jigs can be dismounted when the
transducer holders are properly connected to the pipe as shown in Figure 22.
72.120.606/D Page 65 of 211

5.2.3 Using the Sighting Tool

There are two types of sighting tool, one for each angle set. The first type, shown in
Figure 1, is for transducer holders mounted at a 45° angle. There are two tools in a
set, one fits snugly in each transducer holder. Each of the tools has a hole in the
center.
Figure 23: The sighting Figure 24: The sighting tool Figure 25: The stop washer
tool for the 42°/48° for the sighting tool for the
for 45° transducer holders.
transducer holders 42°/48° transducer
. holders.
The second type of sighting tool is made for transducer holders that are mounted on
pipes with a diameter of 10” and less and with 42°/48° transducer holders, ref. Figure
23. This set of tools use the path of light for verification like the first. As the
transducer holder’s mounting angles are not equal, these tools require some
adjustments before they can be used. The set comes with a pair of stop washers,
shown in Figure 25. The tool must penetrate the transducer holder to the same
depth as the transducer.
Figure 24: The sighting tool for the 45°/45° transducer holders
Stop washer
Sighting Tool
Figure 26: A 45°

Sighting tool
sighting tool mounted
in a transducer
holder. Figure 27: A 42°/48° sighting tool with
stop washer mounted in a transducer
holder.
72.120.606/D Page 66 of 211

When using the sighting tool for pipes that have a diameter greater than 10”, insert
the sighting tool into the transducer holder so that the flange of the sighting tool is
flush with the flange of the transducer holder. This is shown in Figure 26.
When using the sighting tool for pipes that are 10” and less, use the measurement
from the special tool in described in section 5.3.1 to find the correct depth for the
transducer. This depth should be the same for the sighting tool. Measure from the
narrow end of the sighting tool and tighten the stop washer at that position. Insert
the sighting tool so that the stop washer is flush with the flange on the transducer
holder, this is shown in Figure 27. There is a groove in the head of this type of
sighting tool shown in Figure 28. Align one sighting tool with the pipe, and rotate the
other until the light is visible. Adjust the sensor holder so that the circle of light is
Rotate
Figure 28: Look through the holes on the sighting tool. Rotate the sighting tool on
the left to get a correct alignment.
seen as described below.
When the transducer holders are properly aligned and the sighting tools are inserted,
it is possible to see a perfect circle of light when looking through the hole in one of the
sighting tools, shown in Figure 29. If there is not enough ambient light, it may be
necessary to shine a light source through the hole in the opposite sighting tool.
Figure 29: A good Figure 30: A bad alignment.

alignment.
72.120.606/D Page 67 of 211

5.2.4 Hot Tapping Transducers Full Size, TFS

If hot tapping is needed, use the same procedure described in Cold Tapping but do
not drill the pilot holes. When the welding of the transducer holders has been
performed and the ball valves are mounted, connect the hot-tapping equipment to the
2" ball valve. Open the ball valve and drill the hole. The hole should be as close to
49.3 mm as possible, but care should be taken to avoid damage to the ball valve. If
possible, use a 49 mm drill. Do the drilling carefully so that a hole without sharp
edges can be obtained.
5.3 Mounting the Ultrasonic Transducers

5.3.1 Determining the Correct Position for the Transducers
Fluenta will use a special gas proof measuring
tool to find the correct position for the
transducers, as shown in Figure 31. The method
is shown in the figure below. This is done on
site during installation of the transducers and
due to the fact that the entire length, including
ball valves and gaskets, is measured. The
transducer is thereafter positioned correctly.
Figure 31: The gas proof measuring tool.
Figure 32: A schematic of the gas-proof measuring tool.
72.120.606/D Page 68 of 211

5.3.2 Edge Flush Transducer Mounting
5.3.2.1 Setting the correct insertion depth

The insertion depth measurement should be performed as usual. When setting the
insertion depth, remember that a retraction of the transducer means that the
insertion depth should be reduced (see Figure 33).
Figure 33: The insertion depth (green arrow) must be reduced (red arrow)
according to the angle of the transducer holder
As a result of the reduced insertion depth, the distance between the transducer tips
will increase (see Figure 34). The transducer tip distance is a parameter that directly
affects the flow velocity calculations, therefore the transducer distance must be
updated in the configuration of the flow computer.
For the FGM 160 the transducer distance can be found in the O&S Console software
under Config – Config Main Page – Mechanical Parameters – Measured (length in m).
For a FGM 130 the transducer distance is either set by command 278 or in the
software:
(/* 53 */ fgm1.parameter.TransDistance = x.xxx; /* (278) transducer distance [m] */
72.120.606/D Page 69 of 211

Figure 34: When the transducers are retracted, the transducer distance will increase
from the original distance (red arrow) to the new transducer distance (green arrow).
This must be updated in the flow computer.
72.120.606/D Page 70 of 211

5.3.2.2 45° installations
For an installation where the transducer-

holder angles are 45°, the retraction
needed for each transducer is 18mm (see
Figure 35). The transducer distance must
then be increased with 36mm (2x18mm)
in the flow computer configuration.
Figure 35: Edge-flush position for a

45° transducer holder
5.3.2.3 48°/42° installations
For an installation where the transducer-holder angles are 48° and 42°, the retraction
needed for each transducer is 16.2mm for the 48° transducer (see Figure 36), and
20mm for the 42° transducer (see Figure 37). The transducer distance must then be
increased with 36.2mm (16.2mm+20mm) in the flow computer configuration.
Figure 36: Edge-flush position for a 48°

transducer holder Figure 37: Edge-flush position for a
42° transducer holder
72.120.606/D Page 71 of 211

5.3.3 Insertion of the Transducer Full Size (TFS)

When the transducer holders and ball valves are installed the ultrasonic transducers
may be inserted. This shall ONLY be done by personnel certified by Fluenta. If this is a
first time installation, the transducer holder should be checked for liquid and drained
prior to installation.
NOTE:
During transducer installation the power to FGM 160 must be turned
OFF!
Verify that the installed ball valves are gas tight (no gas leaks). This should be done
by the on-site personnel - using a gas monitoring device. Measure and adjust the
installation depth of each transducer, which is set by fastening the A-lock lock-ring.
Mount the transducer/packbox. Open the ball valve, and push the transducer all the
way in, until meeting the A-lock locker ring. Fasten the A-lock nut to the transducer
packbox.
1 2 Open the ball valve

Mount the transducer
3 4 Screw in the
Insert the transducer locking nut
Figure 38: Mounting the Transducer Full Size.
6. Field Computer Installation

In order to reduce signal loss and maintain signal quality, the length of the signal
cables should be kept as short as possible. Thus the FGM 160 (Ex-d/e Enclosure)
must be mounted close to the spool piece/ transducers. The FGM 160 has lugs that
enable easy mounting on either a separate frame or on top of the spool piece by
brackets.
6.1 The Field Computer Mounting Brackets

The field computer can be mounted on existing infrastructure, or a custom mounting
bracket. The custom mounting bracket frame comes in four versions. The first is
shown in Figure 39 (a), and includes legs for a free standing mount, as well as two
brackets for mounting a separate AC to DC converter in an Ex-d housing. The bracket
shown in b) is the same, except it does not include a mounting bracket for an AC to
DC converter. The mounting bracket in (d) shows a bracket that mounts onto the
existing infrastructure. The bracket in c) shows the same bracket as (d) with a
bracket for an AC to DC converter.
72.120.606/D Page 72 of 211
a) b)
c) d)
Figure 39: The FGM 160 Field Computer mounting bracket versions.
72.120.606/D Page 73 of 211

6.2 Electrical Wiring

Power and signal cables between the FGM 160 and the local equipment room should
be pulled and ready for termination before the installation starts. The routing and
preparation of the cables is not normally part of Fluenta’s scope of work.
External wiring is to be carried out according to:
FGM 160 - Field Wiring Diagram, Fluenta Doc.no.: 77.120.509 [3].
Power source should not be connected until verification of supply voltage has been
performed. Main fuses should not be inserted at any stage of the installation phase
All cables should be connected to the terminals in the Ex-e enclosure of the FGM 160.
The blue terminals are IS (Intrinsically Safe) and are connected to the field computer
through internal IS barriers. The gray terminals are not connected to an IS barrier,
and are meant for signals between the field computer and safe area equipment and
systems.
Figure 40: Ex-e enclosure terminals overview.
72.120.606/D Page 74 of 211

6.2.1 Cable Preparations

The below described steps should be carried out at both ends of the cables. However
the installation of glands is not applicable for the Local Equipment Room.
· Verify the labeling/tag name on the cable.
· Verify whether the cable is “megged” or not.
· Cut the cable to a length that allows slack.
· Pull the cable through its respective gland, and make sure that the cable gland
is of the required type and size.
· Terminate and secure the cable and cable gland according to instructions for
the specific cable gland.
· Strip and terminate the conductors and screen according to good workmanship.
· If the cable is not “megged”, it should be carried out at this point.
· The conductors and screens should also be checked for continuity
6.2.2 Power Cable
The FGM 160 requires a 24 VDC power supply

(ref. section 5.24.3 Equipment Information).
Keep the twisting of the conductor pair and
route the conductors to the power input
terminals (ref. Figure 40). If applicable,
terminate the screen to the PE Earthbar.
24VDC
6.2.3 Ultrasonic Transducer Cables

Figure 41: Power to the FGM 160.
The ultrasonic transducer cables are already prepared from the Fluenta production.
These cables should be handled with care.
Verify the labeling/tag name on the cable.
Pull the cable through its respective gland;
make sure that the cable gland is of the
required type and size. Secure the cable
and cable gland.
Upstream Ultrasonic
It is recommended that the cable between
Transducer
the FGM and the transducers is kept as
short as possible, 3 meters is supplied as a
standard. If this is not possible to Downstream Ultrasonic
accomplish, the cable length should not Transducer
exceed 10 meters. For other lengths than
standard, Fluenta must be notified.
Figure 42: Connecting the Ultrasonic

Transducers to the FGM 160.
72.120.606/D Page 75 of 211

The ultrasonic transducers shall be connected as follows. This is done at the Fluenta
production facilities.
Upstream:
Ch1Up–IS
Ch1Up+IS
Ch1Up_G
Downstream:
Ch1Dn-IS
Ch1Dn+Is
Ch1Dn_G
Keep the twisting of the conductor pairs when connecting to terminals.

All conductors of the prefabricated transducer cables are labeled according to the
signal names of the Ex-e terminals (ref. Figure 43)
Figure 43 – Connection details for ultrasonic transducers.
72.120.606/D Page 76 of 211

6.2.4 Connecting the Pressure and Temperature Transmitters

Pressure and temperature transmitters shall be connected directly to the connection
terminals in the Ex-e enclosure, no barriers are required, as these are built-in in the
IS Barrier module within the FGM 160. For detailed information regarding the built in
barriers and the optional grounding wire shown in Figure 44, please refer to: FGM 160
– Hazardous Area Installation Guidelines [2].
The FGM 160 can interface either to 4-20 mA current loop transmitters or HART
transmitters. Depending on the transmitter interface to the FGM 160, a connection
described in figures below should be used. Up to four HART transmitters can be
connected to the HART input terminals, e.g. if condition based maintenance scheme is
utilized with double or dual transmitters.
The pressure and temperature inputs at the FGM 160 are always configured as active
current loop inputs (i.e. the pressure and temperature transmitters are always
powered form the FGM 160 field computer).
T P
Optional grounding wire.
4-20mA / HART
4-20mA / HART
Figure 44: Pressure and temperature transmitter hook-up.
72.120.606/D Page 77 of 211

Figure 45 – FGM 160 – 4-20 mA pressure and temperature transmitter connections.
Figure 46 – Pressure and Temperature HART transmitter connection.
72.120.606/D Page 78 of 211

6.2.5 Control Room and Data Cables

The FGM 160 Flow Computer can be connected to the control room in several different
ways. These allow the DCS or SCADA software in the control room to communicate
with the FGM 160 Flow Computer. The following are the connection options:
· DCS port, Modbus protocol (RS-485)

· Three (3) 4-20 mA, with additional three (3) as option.
· HART interface (optional).
· One (1) Pulse, Frequency or Level output (optional).
Control Room
4-20mA (HART)
Pulse/frequency/
level
DCS port, Modbus
Operator
Console Service port
Figure 47: Data and Signal Cables.
The Service port is for the Operator & Service Console. This connection must be
available in the safe area in order to enable Fluenta’s support personnel to check the
meter’s performance, configure the meter and upload new firmware. Figure 47 shows
the different connections. Operator Console and DCS wiring is normally not a part of
Fluenta’s scope of work.
72.120.606/D Page 79 of 211

6.2.5.1 DCS Port, Modbus

The FGM 160 can be interfaced to a DCS Modbus system by a RS 485 signal interface.
Normally a 2-wire interface is used, but 4-wire interface can also be used.
For detailed information regarding the DCS port wiring, please refer to:
FGM 160 – DCS Modbus Interface Specifications [4].
DCS Modbus Interface is disabled in FGM 160 Foundation Fieldbus configuration
6.2.5.2 Foundation Fieldbus Output

In FGM 160 FF configuration 4-20mA Outputs are not available. They are replaced by
Foundation Fieldbus Outputs. Wires for FF should be connected to FF_1 and FF_2
outputs marked on the Figure below:
Figure 48: Foundation Fieldbus Connection
6.2.5.3 Service Port

The wiring of the service port is similar to the DCS port wiring.
Please refer to: FGM 160 – Operator Console Description [5], for more detailed
information.
6.2.5.4 Current Loop Outputs (4-20mA)

The FGM 160 has three operational 4-20mA current loop outputs as default, with
additional three as an option.
Each of the current loop outputs can be configured either as active or passive output.
In active output configuration, the current loop is powered from the FGM 160 field
computer. In passive output configuration, an external power source is required.
In default configuration, all current loop outputs are configured as active outputs.
72.120.606/D Page 80 of 211
The current loop outputs can be configured as follows:
- Analog output.
The output is assigned to a specific parameter/process variable and
configured with a desired range.
- Alarm status output.

The output can be configured as a specific alarm output (e.g. temperature
alarm) or as a general global alarm output.
Alarm level can be set to 4mA or 20mA.
- Level indicator output.

The output can be configured to shift from 4mA to 20mA (or opposite) at a
certain level of the assigned variable.
Current Loop Outputs are replaced by Foundation Fieldbus Outputs in FGM 160
Foundation Fieldbus configuration.
6.2.5.4.1 Active Output Configuration (Default Configuration)

In active output configuration the current loops are powered from FGM 160 computer
(30V loop voltage).
72.120.606/D Page 81 of 211

In active output configuration:

- “CLx out” terminal is connected to CL-GND.
- Current loop is connected between
CL+Supply and “CLx in” terminals.
( as default all “CLx out” terminals are connected to CL-GND by jumpers at the terminal blocks)
Figure 49: Active output current loop(s), wiring
72.120.606/D Page 82 of 211

6.2.5.4.2 Passive Output Configuration

In passive output configuration the current loops are powered from an external loop
power source (5V – 50V, see section 6.2.5.4.4, Load / Loop Voltage Limitations, for
more details).
In passive output configuration:

- Current loop is connected between
“CLx in” and “CLx out” terminals.
- The jumpers between “CLx out” terminals
and CL-GND (installed by default) must
be removed.
Figure 50: Passive output current loop(s), wiring CL1-in

6.2.5.4.3 Current Loop Outputs Details
72.120.606/D Page 83 of 211

CL1-out
The current loop outputs of the FGM 160 are

galvanic isolated from the rest of the FGM 160 field
computer.
They are however not individually isolated with
respect to each other (they all share the same
ground reference point).
The outputs are protected against reverse polarity.
See Figure 51 for detailed schematic of the current
loop outputs.
6.2.5.4.4 Load / Loop Voltage Limitations

A typical load resistor value is 250Ω.
This value gives a voltage on the DCS input in the
range of 1 – 5V.
Active Output Configuration

In active output configuration the loop voltage is
30V.
Minimum loop resistance: 100Ω.
Maximum loop resistance: 1350Ω.
Passive Output Configuration

Minimum loop voltage: 5V.
Maximum loop voltage: 50V.
Minimum loop resistance:
- Loop voltage < 30V: Rloop min. = 100Ω.
- Loop voltage > 30V:
Rloop min. = (Loop voltage - 28V) x 50 [Ω].
Maximum loop resistance:
Rloop max. = (Loop voltage - 3V) x 50 [Ω].
Table 3 Min. /max. loop resistance

at typical loop voltages.
Loop voltage Rloop min. Rloop max.
12 V 100 Ω 450 Ω
24 V 100 Ω 1050 Ω
30 V 100 Ω 1350 Ω
36 V 400 Ω 1650 Ω
48 V 1000 Ω 2250 Ω
Figure 51: Current loop outputs, details
72.120.606/D Page 84 of 211

2300.0
2100.0
1900.0
1700.0
Load resistor [Ω]
1500.0
1300.0 Current Loops

1100.0
Operating Range
900.0
700.0
500.0
300.0
100.0
0 5 10 15 20 25 30 35 40 45 50
Loop voltage [V]
Figure 52: Current loop outputs, Load/Voltage limitations
6.2.5.4.5 Restrictions of the Current Loop Outputs

High side load / Low side load
The load resistor should normally be connected on high side (see Figure 53 and Figure
54). Low side load can alternatively be used, but only when a single current loop
outputs is used/connected. If more than one current loop output is used and load
resistor is connected on low side, the readings on each output will show erroneous
values. The reason for this is that the current from each output will disperse over all
connected outputs. (see Figure 55 and Figure 56)
+30V +30V
Load
resistor
CLx-in
CLx-in
Low side load
High side load CLx-out
CLx-out
Load
ONLY for single resistor
output configuration
0V 0V
Figure 53: Current loop active output, High side load and Low side load
+ +
CLx-in
Load
resistor
External power
External power
Low side load

CLx-in
CLx-out
High side load

Load
CLx-out
ONLY for single resistor
output configuration
- -
Figure 54 Current loop passive output, High side load and Low side load
72.120.606/D Page 85 of 211

30V 30V
CLx-in CLx-in
High side loads
CLx-out CLx-out
CLx-in CLx-in
Low side loads
CLx-out CLx-out
0V
0V
Figure 55 Multiple current loop outputs, Active output configuration
+ +
External power
External power
CLx-in CLx-in
High side loads
CLx-out - CLx-out -
CLx-in CLx-in
Low side loads
CLx-out CLx-out
Figure 56 Multiple current loop outputs, Passive output configuration
72.120.606/D Page 86 of 211

6.2.5.5 HART Output

One of the current loop outputs (CL6) can be configured and used as a HART
communication channel.
For detailed information regarding wiring of the HART output channel, please refer to:
FGM 160 – HART Output Interface Specification [6].
6.2.5.6 Pulse/Frequency/Level Output

As an option, the FGM 160 can be configured with one passive pulse/frequency/level
output.
This output can be configured in three different ways:
- Pulse output configuration.
The pulse signal can be used e.g. to interface an external
totalizer/counter.
- Frequency output configuration.
The frequency signal can be used as an alternative to analog current loop
output.
- Level output configuration.
This signal can e.g. be used for alarm or status output.
6.2.5.6.1 Voltage / Current Limitations

Maximum voltage: 30V
Maximum current: 40 mA (output is protected by a 62mA internal fuse)
Figure 57 FGM 160 Pulse/frequency output connections
72.120.606/D Page 87 of 211

Figure 58 FGM 160 Pulse/frequency output connections. Without external power
72.120.606/D Page 88 of 211

6.3 Upgrading from the FGM 130

It is relatively simple to upgrade an existing FGM 130 installation to the FGM 160.
Existing mounts can be used, although the transducers must be replaced, as the FGM
160 uses upgraded Ultrasonic Transducers, and the signal is not backward compatible
with the Ultrasonic Transducers used with the FGM 130. The existing temperature
and pressure sensors can be used, and the fiber optic cables can be re-used for DCS
signal transmission with the addition of an RS485 optical converter. The figure below
shows the similarities and differences between the FGM 130 and FGM 160 setups.
FGM 130 Flow

Computer
Field
Electronics
FGM 130
Control Room
Sensor Cables
Power Cables
Data Cables
Operator
Console
FGM 160 FGM 160 Flow

Computer
Safe
Area
Figure 59 FGM 130 –> FGM 160 upgrade
72.120.606/D Page 89 of 211

The table below shows the components of the FGM 130 that can be re-used when
upgrading to the FGM 160.
FGM 130 FGM 160
Flow Computer No Replaced by FGM 160 Computer

Field Electronics
No Integrated in FGM 160 Computer
Enclosure
Ultrasonic Sensors No New FGM 160 sensors
Pressure Transmitter Yes Interface directly to FGM 160 Computer
Temperature Transmitter Yes Interface directly to FGM 160 Computer
Power Cable Yes Power or Communication
Fiber Optic Signal Cable Yes Communication (RS422/RS485)
Sensor Holders Yes
DCS/SCADA Interface Yes Compatible, with an additional HART interface
72.120.606/D Page 90 of 211

7. References
[1] FGM 160 Preservation, Packing, Unpacking and Storage Procedure
[2] FGM 160 – Hazardous Area Installation Guidelines
[3] FGM 160 - Field Wiring Diagram, Fluenta Doc.no.: 77.120.509
[4] FGM 160 – DCS Modbus Interface Specifications
[5] FGM 160 – Operator Console Description
[6] FGM 160 – HART Output Interface Specification
72.120.606/D Page 91 of 211

8. Space Requirements for the TFS
72.120.606/D Page 92 of 211

Hazardous Area Installation Guidelines
5.3 Hazardous Area Installation Guidelines
1. Purpose ...................................................................................................... 94
2. Abbreviation/Definitions ................................................................................ 94
2.1 Abbreviations........................................................................................................................... 94
2.2 Definitions................................................................................................................................ 94
3. General ....................................................................................................... 94
4. Unpacking ................................................................................................... 94
4.1 Inspection of Goods ................................................................................................................. 94
5. Ex-Certificaton and Marking ........................................................................... 94
5.1 Ex-Classification Marking ......................................................................................................... 94
5.2 FGM Sensor Marking ............................................................................................................... 95
5.3 Equipment Information ........................................................................................................... 95
5.4 Pressure and Temperature Transmitter Interface Specifications ........................................... 96
5.5 Manufacturer Information ...................................................................................................... 97
6. References .................................................................................................. 97
7. APPENDIX 1 ................................................................................................ 97
72.120.606/D Page 93 of 211

1. Purpose
This document provides installation guidelines for the FGM 160 Flare Gas Meter in
order to ensure safe use of the system in a potential explosive atmosphere.
2. Abbreviation/Definitions
2.1 Abbreviations
FGM 160 Fluenta Flare Gas meter, Model FGM 160
2.2 Definitions
Ex-d/e - Equipment in Ex-d explosion proof enclosure and connection
housing in Ex-e enclosure.
3. General
This document is not a complete installation and hook-up instruction for the FGM 160.
For complete installation instructions, please refer to Installation and Hook-Up
Instructions.
4. Unpacking
4.1 Inspection of Goods
Installation of the equipment supplied by Fluenta must never occur without the
inspection of the supplied goods carried out first. This should be performed according
to relevant quality assessment schedules.
5. Ex-Certificaton and Marking

5.1 Ex-Classification Marking
Make sure that the FGM 160 is certified for the area and hazardous zone it is intended
to be installed in. The system marking is shown in Figure 60. This marking states
which areas the Ex-d or Ex-d/e Field Computer and the ultrasonic transducers are
certified for, according to ATEX Directive 94/9/EC requirements. The ATEX label is
fixed to the right hand side of the FGM 160 Field Computer. Other Ex-marking may be
applied according to the area of installation, e.g. CSA, GOST etc.
72.120.606/D Page 94 of 211

Figure 60: ATEX certification marking of the Fluenta Flare Gas Meter, FGM 160.
5.2 FGM Sensor Marking

The FGM ultrasonic transducers are marked with a tag identifying the sensor serial
number and the Ex-classification, ref. Figure 61.
Figure 61 FGM 160 Sensor Label Plate.
5.3 Equipment Information

The following ratings apply for the FGM 160 Flare Gas Meter:
*)
Electrical rating (input power) +24 VDC nom. (20 – 32 VDC)
72.120.606/D Page 95 of 211

Maximum power consumption 13 W

Input power fuse rating 1.25 A
Ingress Protection, Ex-d/e Version;

Ex-d enclosure IP 66
Ex-e enclosure IP 66
*)
: The FGM 160 requires +24 VDC input. If +24 VDC is not available, an optional
110-230 VAC/24 VDC converter can be supplied by Fluenta, mounted in an Ex-
d explosion proof enclosure.
Note!
The FGM 160 Field Computer is not equipped with an ON/OFF switch. Thus, it should
be assumed that power is present unless it is made absolutely sure that no power is
present at the terminals.
5.4 Pressure and Temperature Transmitter Interface

Specifications
The FGM 160 can interface to Ex-i/Ex-d classified Pressure and Temperature
transmitters with 4-20 mA/HART interface, through their dedicated IS-terminals only.
Ref. terminal block connections inside the FGM 160 Field Computer Ex-e enclosure.
Io = 0.09A Uo = 27.3V
Ro= 304 ohm Po= 0.62W
Co=0.088yF Lo = 3.5mH
Lo/Ro=58uH/ohm
Figure 62 Specifications for 4-20 mA/HART inputs from Pressure and Temperature
transmitter connections.
72.120.606/D Page 96 of 211

5.5 Manufacturer Information

The FGM 160 Flare Gas Meter is manufactured by Fluenta AS:
Visiting address: Telephone/Fax:

Sandbrekkeveien 85 Telephone: +47 55 29 38 85
Nesttun, Bergen Fax: +47 55 13 21 60
Norway
Mail address: E-mail addresses:

P. O. Box 115, Midtun Sales: sales@fluenta.com
N-5828 Bergen Support: support@fluenta.com
Norway
6. References
FGM 160 Installation & Hook-Up Instructions.
7. APPENDIX 1
Connection of Ex Pressure and Temperature transmitters is outlined in Figure 63.
Requirements for transmitters that do and do not comply with IEC 60079-11 Ed. 5,
Clause 6.3.12 is listed below, as well as requirements for transmitters with Ex-d
protection.
Requirements for transmitters which Requirements for transmitters which do

comply with IEC 60079-11 Ed. 5, not comply with IEC 60079-11 Ed. 5,
Clause 6.3.12 Clause 6.3.12
(Dielectric strength test): (Dielectric strength test)
Intrinsic safe parameters for each Intrinsic safe parameters for each
transmitter: transmitter:
Ui = 27.4V (minimum) Ui = 27.4V (minimum)

Ii = 91mA(minimum) Ii = 91mA(minimum)
Pi = 0.63W(minimum) Pi = 0.63W(minimum)
Special conditions for safe use:
Grounding cable with minimum 4mm2

cross section connected from transmitter
housing to protective earth.
Requirements for transmitters with
Ex d protection:
No special requirements
72.120.606/D Page 97 of 211

Figure 63 Ex Pressure and Temperature transmitter connections.
72.120.606/D Page 98 of 211

Operating Instructions
6. OPERATING INSTRUCTIONS
6.1 Operating Instructions
6.2 DCS Modbus Interface Specifications
6.3 HART Outputs Interface Specifications
6.4 Operator Console Description
72.120.606/D Page 99 of 211

6.1 Operating Instructions

1. Purpose .....................................................................................................101
2. Abbreviations/Definitions .............................................................................101
2.1 Abbreviations: ...................................................................................................................................... 101
2.2 Definitions: ........................................................................................................................................... 101
3. General Information ....................................................................................101
3.1 Hardware Description ........................................................................................................................... 101
3.1.1.1 Electrical Connections .............................................................................................................. 103
3.1.1.2 Power Supply ............................................................................................................................ 103
3.1.1.3 Input Signals ............................................................................................................................. 103
3.1.1.3.1 Ultrasonic Transducers ..................................................................................................... 103
3.1.1.3.2 Pressure and Temperature Transmitters .......................................................................... 103
3.1.1.4 Output Signals .......................................................................................................................... 103
3.1.1.4.1 Modbus Communication (RS-485) .................................................................................... 103
3.1.1.4.2 Current Loop Outputs ....................................................................................................... 103
3.1.1.4.3 HART Output ..................................................................................................................... 103
3.1.1.4.4 Pulse/Frequency Output................................................................................................... 103
3.1.2 Electronic Modules in FGM 160 ................................................................................................... 105
3.1.2.1 Digital Signal Processing (DSP) Module .................................................................................... 105
3.1.2.2 Analogue Front End (AFE) Module ........................................................................................... 105
3.1.2.3 Pressure & Temperature (P&T) Module ................................................................................... 105
3.1.2.4 Input/Output (I/O) Module ...................................................................................................... 105
3.1.2.5 Intrinsic Safety Barrier (IS Barrier) Module .............................................................................. 105
3.1.2.6 Surge Protection Module ......................................................................................................... 105
3.1.2.7 Local Display Module................................................................................................................ 105
3.1.3 Non Resettable Counter Function ............................................................................................... 105
3.2 Firmware Description ........................................................................................................................... 106
3.2.1 DSP Module ................................................................................................................................. 106
3.2.2 P&T Module ................................................................................................................................. 106
3.2.3 I/O Module................................................................................................................................... 107
3.3 Device Integrity..................................................................................................................................... 107
3.3.1 Self Checking ................................................................................................................................ 107
3.3.2 Watchdog Timer .......................................................................................................................... 107
3.3.3 Flash Memory .............................................................................................................................. 107
3.4 Configuration and Operating Software ................................................................................................ 107
4. Operating Procedure ....................................................................................108
4.1 Introduction .......................................................................................................................................... 108
4.2 Power-Up Sequence ............................................................................................................................. 108
4.3 Field Computer Configuration .............................................................................................................. 109
4.4 Local Display Functions......................................................................................................................... 110
4.5 Error Check and Troubleshooting ......................................................................................................... 111
4.5.1 Error Check with Local Display ..................................................................................................... 111
4.5.2 Error Check with O&S C ............................................................................................................... 112
5. References .................................................................................................112
6. Appendix I – System Configuration File ..........................................................113
72.120.606/D Page 100 of 211

1. Purpose
This document describes the Fluenta Flare Gas Meter, FGM 160 hardware and
software, and the device integrity.
2.1 Abbreviations:
DCS Distributed Control System
O&S C Operator & Service Console
2.2 Definitions:
Operator & Service Console - PC software with graphical interface for configuring
and monitoring the FGM 160 Field Computer
3. General Information
3.1 Hardware Description
The FGM 160 Field Computer, illustrated in Figure 64, is designed as a distributed
system. The FGM 160 consists of five or six modules, the Digital Signal Processing
(DSP) module, the Analogue Front End (AFE) module, the Pressure & Temperature
(P&T) module, Input/Output (I/O) module, Intrinsic Safe Barrier (IS Barrier) module,
Surge Protection module and the Local Display. A distributed system gives several
advantages. This design will be more flexible with respect to future expansions and
modifications, as the total processing load for the system can be divided on several
modules. Thus, the danger of overloading a single CPU unit is reduced.
Figure 64 – FGM 160 Field Computer.
72.120.606/D Page 101 of 211

The FGM 160 is certified for operation in Hazardous Area.
For detailed information regarding Hazardous Area installation and operation, please
refer to Chapter 5. – Section 5.3 Hazardous Area Installation Guidelines and Fluenta
Doc. no. 75.120.200 (FGM 160 Hazardous Area Certificates).
Control Room
Sensor Cables
Power Cables
Data Cables Operator

FGM 160 Flow Console
Computer
Safe
Area
Figure 65 – FGM 160 Hook-Up, with the Field Computer, Ultrasonic Transducers, Pressure and
Temperature Transmitters, and connections to Safe Area equipment.
72.120.606/D Page 102 of 211

3.1.1.1 Electrical Connections

Please refer to Chapter 5 – Section 5.2 Installation & Hook-Up Instructions, for
detailed information regarding all electrical connections.
3.1.1.2 Power Supply

The FGM 160 requires 24 VDC power supply (nominal). If 24 VDC is not available, an
optional 110-230 VAC/24 VDC converter can be supplied by Fluenta.
For detailed equipment information and equipment ratings, please refer to Chapter 5
– Section 5.3 Hazardous Area Installation Guidelines.
3.1.1.3 Input Signals
3.1.1.3.1 Ultrasonic Transducers

FGM 160 ultrasonic transducers are connected to the FGM 160 Field Computer by
means of the included prefabricated signal cables.
3.1.1.3.2 Pressure and Temperature Transmitters

The FGM 160 can be configured to accept analog 4-20 mA transmitters or HART
compatible transmitters. The pressure and temperature transmitters may be omitted
if the system is configured to get the pressure and temperature data from the DCS
system (Modbus communication link).
3.1.1.4 Output Signals
3.1.1.4.1 Modbus Communication (RS-485)

The FGM 160 has two separate Modbus communication ports.
One is dedicated for communication with a DCS system. The second is a service port
for configuration and monitoring of the FGM 160 system.
DCS Output is disabled in FGM 160 Foundation Fieldbus configuration.
3.1.1.4.2 Foundation Fieldbus Output

Maximum 4 parameters can be predefined according to customer’s requirement. List
of parameters available for the customer can be found in Fluenta AS doc. No.
72.120.305 (all parameters available using Modbus Serial Interface are accessible
using Foundation Fieldbus output).
3.1.1.4.3 Current Loop Outputs

Up to 6 current loop outputs are available for output of selectable parameter values,
where 3 analogue output is configured as default. The 4-20 mA current loop output
channels can be configured as active or passive outputs.
4-20 mA Outputs are replaced by FF Outputs in FGM 160 Foundation Fieldbus
Configuration
3.1.1.4.4 HART Output

One of the current loop outputs can also be configured for HART output
communication. Refer to Chapter 6 – Section 6.3. HART Output Interface Specification
for details.
3.1.1.4.5 Pulse/Frequency Output
72.120.606/D Page 103 of 211

The FGM 160 can also be configured to provide a pulse or frequency output signal.
The pulse output will represent a totalised increment (of e.g. volume or mass),
whereas the frequency output will represent a process parameter (e.g. volume flow
rate, mass flow rate etc.)
72.120.606/D Page 104 of 211

3.1.2 Electronic Modules in FGM 160
3.1.2.1 Digital Signal Processing (DSP) Module

The Digital Signal Processing module is, as its name indicates, the processing module
in the system. The DSP Module generates the ultrasound measurement signals and
controls the measurement sequences. It collects data from the other module registers
and performs flow calculations based on these data. All calculated parameters are
stored in defined registers. All of these registers are available for the Operator &
Service Console through the Modbus service port at the I/O Module. A selection of
these registers is also available for the DCS system (through the DCS port at the I/O
Module).
3.1.2.2 Analogue Front End (AFE) Module

The Analogue Front End Module is the interface between the DSP Module and the
ultrasonic transducers via the IS-Barrier unit. At the AFE Module, measurement
signals are multiplexed and switched between upstream and downstream direction.
3.1.2.3 Pressure & Temperature (P&T) Module

The Pressure & Temperature Module collects pressure and temperature information
from external sensors via 4-20 mA current loop or HART Interface. All pressure and
temperature data are stored in predefined registers available for the DSP Module.
Thus, the DSP unit can retrieve P&T parameters in a minimum of time.
3.1.2.4 Input/Output (I/O) Module

The Input/Output Module is the interface between the FGM 160 in hazardous area and
equipment in safe area. At the I/O Module, 24 VDC (nom.) supply voltage is converted
to the required operational voltages for the other modules. Further, all signals and
communication to and from the DCS system and Operator & Service Console are
handled by this unit.
3.1.2.5 Intrinsic Safety Barrier (IS Barrier) Module

The Intrinsic Safety Barrier Module ensures the intrinsic safety for operation of the
ultrasonic sensors mounted in hazardous area In addition, the IS-Barrier Module
includes safety barriers for the P&T transmitters. Thus, P&T transmitters with “Ex i”
certification can be interfaced directly to the FGM 160. For specifications regarding the
P&T transmitter barriers, please refer to Chapter 5 – Section 5.3 Hazardous Area
Installation Guidelines.
3.1.2.6 Surge Protection Module

The Surge protection Module protects the power input and the signal output lines from
externally generated spikes, surges and overvoltage.
3.1.2.7 Local Display Module

The Local Display (LD) Module is the front unit, visible through the Ex-d safety glass.
At the LD, a set of predefined metering process parameters can be viewed. Further,
four LEDs give the status of Power, Alarms, Measurement and Communication.
3.1.3 Non Resettable Counter Function

The non-resettable counter function will record and keep the totalized volume and
mass. The totalized values are accessible through the DCS Modbus interface or
through the Operator & Service Console.
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3.2 Firmware Description

In the following sections, a general description of the firmware for the different
modules is outlined.
3.2.1 DSP Module

· The DSP Module initializes the system at start-up. Tasks are set to initial states
and the system is ready for operation.
· The signals transmitted by the ultrasound transducers are generated by the DSP
Module. The sequencing is controlled by this module, and depending on the
velocity of the medium in the pipe, either both Chirp and CW signals or just Chirp
signals are used for the flow measurements. One ultrasonic transit time
measurement is always succeeded by an ultrasonic transit time measurement in
the opposite direction.
· Data sampling and signal processing are carried out after a specified number of
sequences. The DSP module then calculates the difference in transit time
measurements and calculates the parameters available in the FGM system.
· Flow velocity and volume flow rate calculations run continuously, calculating new
values based on data from the P&T module and transit time measurements from
the ultrasonic transducers.
· Gas density and mass flow calculations are calculated based on calculated velocity
of sound and measured pressure and temperature.
· Volume and mass totalising calculations are continuously updated based on
volumetric and mass flow rate calculations.
· All system configuration parameters are stored in the Flash memory (non-volatile
memory) at the DSP Module.
· The DSP Module carries out self checking and evaluation of input and calculated
parameters.
3.2.2 P&T Module

· The P&T Module continuously collects pressure and temperature values from the
external pressure and temperature transmitters mounted downstream of the FGM
160. These readings are used in calculations performed by the DSP module.
· In addition to the external temperature reading, the P&T also reads the internal
temperature value. This value is used to monitor the internal temperature in the
Ex-d enclosure.
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3.2.3 I/O Module

· The I/O Module handles all signals and communication with systems in Safe Area.
· Data requests and commands from Operator Console are processed by the I/O
Module. A predefined number of accessible parameters are available from the FGM.
Accessible parameters depends on whether 4-20 mA, HART or Modbus is utilized.
· Software downloads to the DSP-, P&T- and I/O Module are carried out by the I/O-
module.
· All data requests from DCS system are handled by the I/O Module; either through
Modbus or HART interfaces.
3.3 Device Integrity

3.3.1 Self Checking
The FGM 160 performs a self-checking sequence, where it checks that inputs from the
transducers and Temperature and Pressure transmitters are within valid range, and
that other functions are operating as intended.
3.3.2 Watchdog Timer

The Watchdog Timer is initialized at start-up, and can not be disabled, ensuring that if
the unlikely situation of system hang-up should occur, the Watchdog Timer will reset
the system forcing a complete reboot and start-up.
3.3.3 Flash Memory

System configuration is stored in Flash Memory (non-volatile memory). In case of a
power break, all system configurations are reloaded from the Flash memory
3.4 Configuration and Operating Software

Through the FGM 160 Operating & Service Console (O&S C), the operator can monitor
process data, configure the meter and specify process data to be saved to a data log
file for later analysis. The O&S C further enables the operator to operate the meter
remotely, by using e.g. a RS 485 / TCP/IP converter and remote control software.
It should be noted, the O&S C is required to replace the default settings with actual
applicable settings provided by customer. Fluenta service engineers and partners will
always setup the FGM 160 according latest submitted parameters from the Client
when installing and commissioning the FGM 160. Fluenta’s service engineers and
partners carry always with them the O&S C.
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4. Operating Procedure
4.1 Introduction
This section provides information about how to operate the FGM 160 field computer.
The FGM 160 is a field mounted stand-alone ultrasonic gas flow measurement system,
and does not require any safe area communication device in order to operate.
However, in order to continuously monitoring data and the meter performance, it is
recommended to use the Operator & Service Console (O&S C). This program will
provide hands-on process and status data continuously, with possible remote access
to the FGM 160 system from any remote system with the appropriate remote control
software installed.
4.2 Power-Up Sequence

The power-up sequence describes the necessary handling of the FGM 160 in order to
ensure correct operation.
1. Connect all power, input and output signals and communication cables according to
the project specification and all relevant procedures and instructions.
2. Make sure that the power cable is connected to a suitable power source, either
directly to a 24 VDC supply or through a 110-240 VAC / 24 VDC converter.
3. Turn on the power to the FGM 160. There is no power switch on the FGM 160 Field
Computer, so the power must be turned ON and OFF by an external switch or
similar, preferably in safe area.
4. On startup, the FGM 160 will go through a boot and an initialization sequence
before entering the standard operational (measurement) mode.
5. When the FGM 160 has entered the standard operational (measurement) mode,
the meter will, according to the system configuration, carry out transit time
measurements, retrieve pressure and temperature data, calculate volumetric and
mass flow rates and either actively output a set of predefined parameters at the
analog 4-20mA outputs, or make a set of process parameters available for DCS
HART or Modbus communication.
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4.3 Field Computer Configuration

The FGM 160 can be configured by using the Operator & Service Console. During
manufacturing, default configuration is entered into the Field Computer. The system
configuration will be modified by Fluenta’s service engineers or partners when
installing and commissioning the meter. At any time this configuration can be changed
by using the Operator & Service Console (O&S C). All system configuration
parameters are stored in non-volatile memory, ensuring that no configuration
parameters are lost in case of power loss. Check Appendix II to learn how to insert or
modify system configuration according to Client parameter list.
Figure 66 Download of system configuration using the Operator & Service Console.
The system configuration parameter file can be downloaded from the FGM 160 using
the Operator & Service Console, ref. Figure 66, by entering the “Config Main Page”
through the “View – Config” menu bar. The system configuration can either be copied
to the clipboard and pasted into a document, or saved directly to a file.
For a full listing of a system configuration file, refer to Appendix I.
Some of the system configuration parameters are also available through the DCS
Modbus registers. However, parameters that should only be accessed by authorized
personnel are not accessible through this communication line. For a full listing of
accessible configuration parameters through the DCS Modbus interface, refer to
Chapter 6 – Section 6.2 DCS Modbus Interface Specifications.
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4.4 Local Display Functions

The FGM 160 is equipped with a local LCD display mounted at the front, and visible
through the Ex-d safety glass. The display shows predefined process parameters from
the FGM 160. Further, 4 status LEDs are visible at the front for the following status
information:
· Power
This LED will have a green light when the system power is ON.
· Status
This LED will light:
GREEN; if no Alarms are active (system status OK).
· Comm
This LED will light:
GREEN; during Modbus frame reception or sending.
· Meas
This LED will blink GREEN at a regular cycle, indicating that ultrasonic
measurement cycle sequence is active.
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4.5 Error Check and Troubleshooting

The operator should not perform extensive troubleshooting beyond what is described
in this section. For repair and module replacement, contact Fluenta AS.
Fluenta AS
Sandbrekkeveien 85
P.O. Box 115, Midtun
N-5828 Bergen
NORWAY
Phone:+47 55 29 38 85
E-mail: support@Fluenta.com
Error check can be carried out by using the Operator & Service Console
NOTE!
Before any work can be carried out with the FGM 160 field computer, a hot
work permit must be obtained.
Do not connect or disconnect any signal wires unless the power is turned
OFF!
Do not open the Ex-d enclosure containing the field electronics in hazardous
area, without first making sure that the conditions approve such action.
Preferably, and as a general rule; the Ex-d enclosure should only be opened
indoors in e.g. a workshop in safe area.
4.5.1 Error Check with Local Display

As described in Section 4.4, 4 LEDs are visible at the front with status information. If
one or more of these LEDs do not have a GREEN light color indicating OK status, the
following status is present and actions should be taken:
· Power
Indication: The LED is not ON (no green light).
Status: System Power is OFF, or LED does not work.
Action: Check that the system Power wires are connected and that 24 VDC
is present at the power input terminals.
· Meas
Indication: The LED is steady OFF or steady GREEN.
Status: The FGM 160 is not in standard operational (measurement) mode.
Action: Check the Alarm log for any error messages indicating any cause for the
problem. Turn the system Power OFF and ON again. If the situation remains
unchanged, contact Fluenta AS for guidance.
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4.5.2 Error Check with O&S C

Through the FGM 160 Operator & Service Console, data can be logged for trend
analysis and evaluation. Data can be logged to a data file and imported in e.g. Excel
spreadsheet for plot and analysis.
Figure 67 By activating the “Log Measurement Data” function at the “Log Data” window,
any or most parameters can be logged to a data file. The data log file name will
be generated automatically based on the current date and time.
By using the Operator & Service Console, it is also possible to carry out remote
diagnostics. Thus, a Fluenta AS service engineer, being granted access to a specific
system by the end operator, can monitor the performance of the meter and carry out
analysis based on logged and live data. This function requires internet connection, and
communication wires to service port.
5. References
[1] FGM 160 – Hazardous Area Installation Guidelines
[2] FGM 160 Hazardous Area Certificates
[3] FGM 160 Installation & Hook-Up Instructions
[4] FGM 160 DCS Modbus Interface Specifications
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6. Appendix I – System Configuration File

********************************************************
********************************************************
****************** ***************
****************** Fluenta AS ***************
****************** FGM 160 parameter list ***************
****************** ***************
********************************************************
********************************************************
Operator Console ver.: 1.040
Field Computer, date and time: 2011-01-17 09:13:25
***************************************
********** System Parameters **********
***************************************
Field Computer Type: FGM 160
Serial number: 2006-0102
Tag number: 1-TAG-1
Company: FLUENTA AS
Instalation:
Description:
Local Display:
SW Version DSP:
EXAMPLE
System Configuration:
Sandbrekkeveien 85
10" LP Flare
Single system (ch1)

Not installed <- You have to change it manualy
0.052 to version number that is installed
SW-app Version I/O: 1.007 using AVR Studio
SW-boot Version I/O: 0.006
SW-app Version P&T: 0.257
SW-boot Version P&T: 0.005
*******************************************
********** Communication Parameters **********
*******************************************
**************** DCS communication **********

------------------------------------------------------------
DCS Modbus Communication: Enabled
Slave address: 224
Type: RTU
Baud rate: 38400
Databits: 8
Parity: No Parity
Stop bit: 2
Register Values: 32 bit floating point (IEEE-754)
Register size in request: 32 bits
Register base address: 1000
***************** HART communication **********
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---------------------------------------------------------------
HART Output Communication: Enabled

Poll address: 1
Primary Variable: Total Volume @ Ref. Conditions
Secondary Variable: Volume Flowrate @ Ref. Conditions
Tertiary Variable: Temperature
Quaternary Variable: Pressure
**************** Service port *****************

-------------------------------------------------------------
Slave address: 1
Type: RTU
Baudrate: 38400
Databits: 8
Parity: None
Stop bits: 2
Register Values: 32 bit floating point (IEEE-754)
**********************************************
************ System Configuration ************
**********************************************
EXAMPLE
Pipe diameter: 0.3800 m
Transducer distance (M): 0.5370 m
Transducer angle: 45.0 deg
******* Units *******

Velocity: m/s
Volume: m3
Volume flow: m3/h (Cubic meter pr. hour)
Mass: kg
Mass flow: kg/h
Pressure: BarA
Temperature: Celsius
Log time for 24h acc. values: 06:00:00
**********************************************
*********** Input Signal Parameters ***********
**********************************************
Pressure input Current Loop (4-20mA)
Temperature input Current Loop (4-20mA)
Current loop ranges
Temperature, 4mA value: 255.15 [Kelvin]
Temperature, 20mA value: 533.15 [Kelvin]
Pressure, 4mA value: 1.013 [BarA]
Pressure, 20mA value: 12.044 [BarA]
Current loop calibration coefficients
72.120.606/D Page 114 of 211

Temperature, offset: 0.0070

Temperature, scale: 0.9963
Pressure, offset: 0.0220
Pressure, scale: 0.9980
Alarm limits
Temperature, Hi limit: 533.15 [Kelvin]
Temperature, Lo limit: 255.15 [Kelvin]
Pressure, Hi limit: 12.044 [BarA]
Pressure, Lo limit: 1.013 [BarA]
**********************************************
********** Output signal parameters **********
**********************************************
******** Current loops, 4-20mA ********

Current loop 1, Parameter: Volume Flowrate @ Act. Conditions
Current loop 2, Parameter: Molecular Weight
Current loop 3, Parameter: Testvalue Current Loop 3
Current loop ranges
EXAMPLE
Current loop 1, 4mA value: 0.00
Current loop calibration coefficients

Current loop 1, offset: -0.1217
Current loop 1, scale: 0.9980
**********************************************
72.120.606/D Page 115 of 211

******** Measurement/Signal Parameters *******

**********************************************
CW velocity limit up (CW/Chirp -> Chirp): 15 m/s

CW velocity limit down (Chirp -> CW/Chirp): 14 m/s
Chirp Pattern: LinFM
Chirp Limit1 (ArcTan FM -> Lin FM): 25 m/s
Chirp Limit2 ( Lin FM ->ArcTan FM): 50 m/s
Low cutoff velocity: 0.05 m/s

Max. velocity: 100 m/s
Min. velocity: 0 m/s
Max. velocity jump: 50 m/s
Max. sound velocity: 500 m/s

Min. sound velocity: 250 m/s
Max. sound velocity jump: 70 m/s
Historical sound vel. weight factor: 40.0
Z Standard:
Z Operational:
EXAMPLE
Ref Temperature (std. conditions):
Ref Pressure (std. conditions):
1.000
1.000
15.00 ºC
1.01325 BarA
**********************************************
******** Sensor Calibration Parameters *******
**********************************************
Serial No, Upstream Transducer (A): 022U-11

Serial No, Downstream Transducer (B): 022D-11
CW frequency: 68.00 kHz
*** Transducer delays (calibration coefficients) ***

Chirp upstream: 31818.0 nsec
Chirp downstream: 33318.0 nsec
CW upstream: 12557.0 nsec
CW downstream: 12576.0 nsec
Delta CW correction: 0.0 nsec
---------------- END --------------------------
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7. Appendix II – Inserting settings from Client

parameter list
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HART Output Interface Specification
6.2 DCS Modbus Interface Specifications
1. Purpose .....................................................................................................126
2.1 Abbreviations:........................................................................................................................ 126
2.2 Definitions: ............................................................................................................................ 126
3.1 Process Parameter Units ....................................................................................................... 127
4. Registers ....................................................................................................127
4.1 Modbus Register Base Addresses.......................................................................................... 127
4.2 Modbus Register Addresses in FGM 160 ............................................................................... 128
4.3 FGM 160 Modbus register map for DCS port ........................................................................ 130
4.3.1 System ID Number ......................................................................................................... 130
4.3.2 Data Time Tag and Primary Measurements Registers .................................................. 130
4.3.3 Secondary Measurements Registers ............................................................................. 131
4.3.4 Totalized Values Registers ............................................................................................. 132
4.3.5 24-Hour Totalized Values Registers ............................................................................... 132
4.3.6 Parameter Unit Registers............................................................................................... 134
4.3.7 Internal System Parameter Registers ............................................................................ 135
4.3.8 Gas Composition Parameter Registers .......................................................................... 135
4.3.9 Real Time Clock Registers .............................................................................................. 136
4.4 Data Encoding of FGM 160 Register Values .......................................................................... 136
4.4.1 Byte Ordering for FGM 160 Register Values.................................................................. 137
4.4.2 Bit Ordering of Each Character or Byte ......................................................................... 138
4.4.3 The “Byte Count” Field .................................................................................................. 138
4.4.4 Register Address Spacing ............................................................................................... 138
5. Number Representation ...............................................................................139
5.1 Single Precision Floating-Point Format.................................................................................. 139
6. Examples ...................................................................................................140
6.1 Function Code 3, Read registers ............................................................................................ 140
6.2 Function Code 16, Write to registers..................................................................................... 140
6.3 Function Code 8; Diagnostics................................................................................................ 141
6.3.1 Sub-function 0 (Return Query Data) ............................................................................. 141
7. Exception responses ....................................................................................141
7.1 Standard Modbus Exception Codes....................................................................................... 141
7.2 Fluenta Defined Exception Code ........................................................................................... 142
8. Physical Layer .............................................................................................142
8.1 RS422 Compatible Master Node (DCS).................................................................................. 142
8.2 Two-Wire Configuration (default configuration)................................................................... 143
8.3 Four-Wire Configuration........................................................................................................ 144
8.4 Cable Specifications ............................................................................................................... 145
8.5 Visual diagnostic .................................................................................................................... 146
8.6 RS485 Modbus Connections at FGM 160 .............................................................................. 146
9. References .................................................................................................148
72.120.606/D Page 125 of 211

1. Purpose
This document describes the Modbus RTU Protocol and the Modbus ASCII Protocol,
which are implemented in the Fluenta Flare Gas Meter, FGM 160 system. Function
codes for operating the system are specified, the various registers are described and
examples of Modbus communication are given.
2.1 Abbreviations:
FGM 160 Flare Gas Meter, Model FGM 160
ASCII American Standard Code for Information Interchange
RTU Remote Terminal Unit
2.2 Definitions:
Modbus A high-level protocol for industrial networks developed by Modicon. It
defines a request/response message structure for a client/server
environment.
Parameters in the FGM 160 are accessible from a serial interface by using the Modbus
protocol. All or just a selected range of parameters in an array can be accessed in a
single read or write operation, 62 in RTU mode and 30 in ASCII mode (due to memory
restrictions in the FGM 160). Some registers contain ‘Read only’ parameters, while
others contain ‘Read / Write’ parameters. All registers in the FGM 160 are 32-bit wide.
Register values are represented as 32-bit floating point values in IEEE 754 format.
The FGM 160 can be configured for Modbus RTU mode or Modbus ASCII mode. In
Modbus RTU mode, each 8-bit byte in a message, contains two 4-bit hexadecimal
characters. In Modbus ASCII mode, each 8-bit byte in a message, is sent as two
ASCII characters.
Function Codes 3, 16 and 8 are implemented.
Function
Description
Code
Read multiple registers, 32-bit floating point format, single precision
3
(IEEE 754).
Write multiple registers, 32-bit floating point format, single precision
16
(IEEE 754).
Loopback test. Only sub-function code 0 is implemented (Return
8
Query Data).
NOTE: Registers accessed by Function Code 3 and 16 are 32-bit floating point
registers, NOT 16-bit integer registers as defined in the Modbus standard.
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The Modbus slave address of the FGM 160 is configurable in the range 1-247 (1 – F7
Hex):
Default Modbus slave address for system 1 and 2 is: 224 (E0 Hex).
Broadcast address (slave address 0) is not supported.
Configuration of the DCS RS 422/RS 485 serial port is:
Parameter Default Setting Optional Settings

Mode RTU ASCII
Baud rate 19200 2400, 4800, 9600, 38400, 57600
Parity Even None, Odd
Number of Data Bits 8 7 (7 data bits shall be used in ASCII mode)
Number of Stop Bits 1 2 (No parity requires 2 stop bits)
3.1 Process Parameter Units
Default and optional parameter units are listed below.
Parameter Default Unit Optional Units

Pressure bar A kPaA, psiA, kg/cm2 Abs
Temperature °C °F
Flow velocity / Velocity of Sound m/s ft/s

Volume flow rate at standard conditions Sm3/h MMSCFD
Volume flow rate at actual conditions m3/h MMCFD
Accumulated volume at standard
Sm3 MMSCF
conditions
Accumulated volume at actual conditions m3 MMCF
Mass flow rate kg/h lbs/h
Accumulated mass kg lbs

Gas density kg/m3 --
4. Registers
4.1 Modbus Register Base Addresses
The FGM 160 Modbus register base addresses are shown below. These are individually
configurable in the range 0 - 65333. However, the offset between succeeding register
base addresses should at least be 200 if system 1 and system 2 is configured with the
same Modbus slave address.
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Modbus Register Default Base Address

DCS register, System 1 1000
DCS register, System 2 2000
The Modbus Register Base Addresses can be read from registers at the fixed register
addresses 65534 and 65535:
Modbus Register Base Address, System 1: 65534

Modbus Register Base Address, System 2: 65535
4.2 Modbus Register Addresses in FGM 160

According to the “Modicon Modbus Protocol Reference Guide” (PI-MBUS-300, Rev.J),
ref. 3, the “Holding register” addresses start at 40001. “Holding registers” are
accessed by function code 3 (read) or by function code 16 (write) in the FGM 160
Modbus interface.
However, “Holding register address” is not the same as the register address in the
data address field of the Modbus message.
The relationship between these addresses is;

“Register address in Modbus message” = “Holding register address” - 40001
Examples:
- Holding register 40001 is addressed as register 0000 in the address field of the
Modbus message. (The function code field already specifies a “holding register”
operation. Therefore the “4XXXX” reference is implicit.)
- Holding register 40108 is addressed as register 107 in the Modbus message

address field.
The register map below refer to the register addresses in the data address field of the
Modbus message (not the “Holding register addresses”).
Also note that the register addresses given in the register map below are OFFSET
addresses relative to the “Modbus Register Base Addresses”.
Examples:
- Modbus Register Base Address for system 1 = 1000 and “Register spacing = 1”
(default configuration):
The “Volume Flow rate at Standard Conditions” register for system 1, can be
found at address 1008 (1000 + 8). This is the register address in the data
address field of the Modbus message, corresponding “Holding register address”
will be 41009.
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- Modbus Register Base Address for system 2 = 2000 and “Register spacing = 1”
(default configuration):
found at address 2008 (2000 + 8). Corresponding “Holding register address”
will be 42009.
- Modbus Register Base Address for system 1 = 1000 and “Register spacing = 2”:
found at address 1016 (1000 + 16). This is the register address in the data
address field of the Modbus message, corresponding “Holding register address”
will be 41017.
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4.3 FGM 160 Modbus register map for DCS port
Register addresses in register map below are OFFSET addresses relative to the
“Modbus Register Base Addresses”.
In default configuration these addresses are set to:
1000, for system 1 DCS registers and,

2000, for system 2 DCS registers.
Address columns “RS=1” and “RS=2”:
RS=1 : valid for configuration “Register spacing = 1” (default configuration).

RS=2 : valid for configuration “Register spacing = 2”.
See section 4.3.4 for detailed description.
4.3.1 System ID Number
Address Def.
Parameter R/W Min Max
RS=1 RS=2 Unit
0 0 ID High word (Production Year) R -- 2002 2099
1 2 ID Low word (Serial number) R -- 0 --
4.3.2 Data Time Tag and Primary Measurements Registers
Address Def.
RS=1 RS=2 Unit
2 4 Data Time Tag - Year R 2002 2091
3 6 Data Time Tag - Month R 1 12
4 8 Data Time Tag - Day R 1 31
5 10 Data Time Tag - Hour R 0 24
6 12 Data Time Tag - Minute R 0 59
7 14 Data Time Tag - Second R 0 59
Volume Flow rate at Standard
8 16 R Sm3/h -- --
Conditions
Volume Flow rate at Actual
9 18 R m3/h -- --
Conditions
10 20 Mass Flow rate R kg/h -- --
11 22 Gas Flow Velocity R m/s -- --
12 24 Gas Flow Velocity w/Threshold R m/s -- --
Gas Flow Velocity,
13 26 R m/s -- --
uncompensated
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4.3.3 Secondary Measurements Registers
Address Def.
RS=1 RS=2 Unit
20 40 Velocity of Sound R m/s -- --
21 42 Gas Density R kg/m3 -- --
22 44 Molecular Weight R g -- --
23 46 Alarm Status *) R 0
Gas Density at Standard
24 48 R kg/Sm3 -- --
Conditions
25 50 Gas density model used R ---- 0 2
26 52 N2 (nitrogen) fraction R % 0 100
30 60 Pressure **) R/W bar A
31 62 Temperature **) R/W °C
32 64 Pressure, HART Transmitter 1 R bar A
33 66 Pressure, HART Transmitter 2 R bar A
34 68 Temperature, HART Transmitter 1 R °C
35 70 Temperature, HART Transmitter 2 R °C
36 72 HART Transmitter Status ***) R 0 6666
*)
: Alarm Status word (bit coded 16-bit word):
To interpret the Alarm status bits, the integer part of the register value should first be
converted to binary format.
Bit 0: Measurement Error

Bit 1: Flow velocity Alarm
Bit 2: Sound velocity Alarm
Bit 3: Density Alarm
Bit 4: Pressure Alarm
Bit 5: Temperature Alarm
Bit 0 is the Least Significant Bit (LSB).
**)
: Pressure and Temperature:
The Pressure and Temperature registers are normally Read Only registers, but the
FGM 160 can be configured to accept pressure and temperature data input from DCS
through these registers.
***)
: HART transmitter status word (4 digit coded, ABCD):
A Status for pressure transmitter 1 in current system

B Status for pressure transmitter 2 in current system
C Status for temperature transmitter 1 in current system
D Status for temperature transmitter 2 in current system
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HART Transmitter Status code:
Code Description
0 Transmitter not found at initialisation.
1 Status OK.
2 Timeout, transmitter not responding.
3 Wrong code in transmitter response.
4 Checksum error in transmitter response.
5 Wrong data format in transmitter response.
6 Illegal number, NaN (Not A Number).
Example:
Status code = 1620:
A=1 : Pressure transmitter 1, status OK.

B=6 : Pressure transmitter 2, illegal number NaN (Not A Number).
C=2 : Temperature transmitter 1 timeout, transmitter not responding.
D=0 : Temperature transmitter 2 not found at initialisation.
4.3.4 Totalized Values Registers
Address Def.
RS=1 RS=2 Unit
Totalized Volume at Standard
40 80 R Sm3 0 1000000
Conditions
Totalized Volume at Actual
41 82 R m3 0 1000000
Conditions
42 84 Totalized Mass R kg 0 1000000
Totalized Vol. at Std. Cond.
43 86 R 1000000 0 1000000
Overflow Count
Totalized Vol. at Act. Cond.
44 88 R 1000000 0 1000000
Overflow Count
45 90 Totalized Mass Overflow Count R 1000000 0 1000000
4.3.5 24-Hour Totalized Values Registers
Address Def.
RS=1 RS=2 Unit
Last 24 Hour Totalized Volume at
50 100 R Sm3 0 --
Std. Cond.
Last 24 Hour Totalized Volume at
51 102 R m3 0 --
Act. Cond.
52 104 Last 24 Hour Totalized Mass R kg 0 --
Start Time for Last 24 Hour
53 106 R HH,MMSS 0,0000 23,5959
Totalisation
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Address Def.
RS=1 RS=2 Unit
(Last-1) 24 Hour Totalized Volume at
54 108 R Sm3 0 --
Std. Cond.
55 110 R m3 0 --
Act. Cond.
56 112 (Last-1) 24 Hour Totalized Mass R kg 0 --
Start Time for (Last-1) 24 Hour
57 114 R HH,MMSS 0,0000 23,5959
Totalisation
58 116 R Sm3 0 --
Std. Cond.
59 118 R m3 0 --
Act. Cond.
61 122 R HH,MMSS 0,0000 23,5959
Totalisation
62 124 R Sm3 0 --
Std. Cond.
63 126 R m3 0 --
Act. Cond.
65 130 R HH,MMSS 0,0000 23,5959
Totalisation
66 132 R Sm3 0 --
Std. Cond.
67 134 R m3 0 --
Act. Cond.
69 138 R HH,MMSS 0,0000 23,5959
Totalisation
70 140 R Sm3 0 --
Std. Cond.
71 142 R m3 0 --
Act. Cond.
73 146 R HH,MMSS 0,0000 23,5959
Totalisation
74 148 R Sm3 0 --
Std. Cond.
75 150 R m3 0 --
Act. Cond.
77 154 R HH,MMSS 0,0000 23,5959
Totalisation
78 156 R Sm3 0 --
Std. Cond.
79 158 R m3 0 --
Act. Cond.
81 162 R HH,MMSS 0,0000 23,5959
Totalisation
82 164 (Last-8) 24 Hour Totalized Volume at R Sm3 0 --
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Address Def.
RS=1 RS=2 Unit
Std. Cond.
83 166 R m3 0 --
Act. Cond.
85 170 R HH,MMSS 0,0000 23,5959
Totalisation
86 172 R Sm3 0 --
Std. Cond.
87 174 R m3 0 --
Act. Cond.
89 178 R HH,MMSS 0,0000 23,5959
Totalisation
(Last-10) 24 Hour Totalized Volume
90 180 R Sm3 0 --
at Std. Cond.
(Last-10) 24 Hour Totalized Volume
91 182 R m3 0 --
at Act. Cond.
93 186 R HH,MMSS 0,0000 23,5959
Totalisation
4.3.6 Parameter Unit Registers
Address Def.
Parameter R/W Optional Settings
RS=1 RS=2 Value
Unit – Velocity
100 200 R 1 (m/s) 2 (ft/s)
(Gas Flow and Sound)
101 202 Unit – Volume R 1 (m3) 2 (MMCF)
Unit – Volume Flow
102 204 R 1 (m3/h) 2 (MMCFD)
Rate
103 206 Unit – Mass R 1 (kg) 2 (lbs)
Unit – Mass Flow
104 208 R 1 (kg/h) 2 (lbs/h)
Rate
105 210 Unit – Pressure R 1 (bar A) 2 (kPa A) 3 (psi A) 4 (kg/cm2 A)
106 212 Unit – Temperature R 1 (°C) 2 (°F)
Abbreviations: MMCF : Million Cubic Feet

MMCFD: Million Cubic Feet per Day
72.120.606/D Page 134 of 211

4.3.7 Internal System Parameter Registers
AS 1 AS 2 Parameter R/W Unit Min Max

110 220 Average Transit Time, Upstream R ns 0 --
111 222 Average Transit Time, Downstream R ns 0 --
112 224 Average Transit Time Difference R ns --
113 226 Transit Time % Used R % 0 100
114 228 Transit Time % Used, Upstream R % 0 100
115 230 Transit Time % Used, Downstream R % 0 00
116 232 Tx Amplitude Upstream R V 0 20
117 234 Tx Amplitude Downstream R V 0 20
118 236 Rx Amplitude Upstream R V 0 20
119 238 Rx Amplitude Downstream R V 0 20
120 240 Corr. Env. Peak Level Upstream R -- 0 20
121 242 Corr. Env. Peak Level Downstream R -- 0 20
122 244 Chirp Pattern Used R -- 0 3
123 246 Transducer Temperature, Upstream R
Transducer Temperature,
124 248 R
Downstream
Internal Temperature, FGM
125 250 R
Electronics
Max. Transducer Temperature,
126 252 R
Upstream
Min. Transducer Temperature,
127 254 R
Upstream
128 256 R
Downstream
129 258 R
Downstream
Max. Internal Temperature, FGM
130 260 R
160 Electronics
Min. Internal Temperature, FGM
131 262 R
160 Electronics
4.3.8 Gas Composition Parameter Registers

140 280 Mol % - C1 R/W % 0 100
141 282 Mol % - C2 R/W % 0 100
142 284 Mol % - C3 R/W % 0 100
143 286 Mol % - C4 R/W % 0 100
144 288 Mol % - C5 R/W % 0 100
145 290 Mol % - C6 + R/W % 0 100
146 292 Mol % - N2 R/W % 0 100
147 294 Mol % - CO2 R/W % 0 100
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4.3.9 Real Time Clock Registers

150 300 RTC Year R/W Year 2002 2091
151 302 RTC Month R/W Month 1 12
152 304 RTC Day R/W Day 1 31
153 306 RTC Hour R/W Hour 0 23
154 308 RTC Minutes R/W Minute 0 59
155 310 RTC Seconds R/W Second 0 59
NOTE:
Not all register parameters listed in Section 4.3.7 and 4.3.8 may be available. They
are although listed in order to enable register mapping for future reading of these
parameters.
4.4 Data Encoding of FGM 160 Register Values

All registers in FGM 160 are 32 bits wide.
Register values are represented as 32 bits floating point values in IEEE 754 format
(single precision).
This is not according to the original Modbus standard [1] which only defines 16 bit
wide integer registers.
To access register values in one of the FGM 160 Modbus registers, one of the following
methods can be used:
- Access as one 32 bits registers (default):

To use this method, the FGM 160 must be configured for: “Register Size” = 32
bits.
This means that the “No. of Registers” field in the request from Modbus master,
is interpreted as: number of 32 bits registers.
This method may be known as “Daniel Option”.
- Access as two consecutive 16 bits registers (option):

To use this method, the FGM 160 must be configured for: “Register Size” = 16
bits.
This means that the “No. of Registers” field in the request from Modbus master,
is interpreted as: number of 16 bits registers.
This method may be known as “Modicon Option”.
It may also be necessary to configure the FGM 160 for: “Register spacing = 2”,
when using this option. (ref. section 4.4.4)
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Examples:
1) “Register Size” = 32 bits. Read two (32 bits) registers starting at addr. 12
(000Chex):
Request:
Modbus Slave Function Data Data No. of No. of Check Modbus
ASCII address code Start Start Regs. Regs. Sum ASCII only
only reg. reg. (MSB) (LSB)
(MSB) (LSB)
: E0 03 00 0C 00 02 XX <CR><LF>
Reply:
Modbus Slave Function Byte Data1 Data1 Data1 Data1 Data2 Data2 Data2 Data2 Check Modbus
ASCII addr. code count (MSB) (LSB) (MSB) (LSB) sum ASCII
only only
: E0 03 08 42 F7 66 66 40 10 A3 D7 XX <CR>
<LF>
2) “Register Size” = 16 bits. Read one (32 bits) register at addr. 12 (000Chex):
Request:
(MSB) (LSB)
: E0 03 00 0C 00 02 XX <CR><LF>
Reply:
Modbus Slave Function Byte Data1 Data1 Data1 Data1 Check Modbus
ASCII addr. code count (MSB) (LSB) sum ASCII
only only
: E0 03 04 42 F7 66 66 XX <CR><LF>
4.4.1 Byte Ordering for FGM 160 Register Values

While the byte order is clearly specified for 16 bits integer register values in the
Modbus standard [1], there is no specification regarding byte order for 32 bit floating
point values.
For addresses and 16 bits data, the Modbus standard [1] defines a “big-Endian”
representation. This means that when a numerical quantity larger than a single byte is
transmitted, the most significant byte is sent first.
As there are no standard definitions regarding byte ordering for transmission of 32 bit
floating point values, the FGM 160 can be configured to handle different byte orders.
The FGM 160 can be configured for the following byte orders:
- DCBA (Most Significant Byte first, then Least Significant Byte, default config.)
- ABCD (LSB first, then MSB)
- CDAB (Most Significant Word first, then LSWord)
- BADC (Least Significant Word first, then MSWord, byte swapped)
The examples on previous page are shown with DCBA byte ordering (MSB first), which
is the default configuration for FGM 160.
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4.4.2 Bit Ordering of Each Character or Byte

The bit order of each character or byte is always in accordance with the Modbus
standard, ref. [1].
The Modbus standard [1] defines this as follows:
“Each character or byte is sent in this order (left to right):

Least Significant Bit (LSB)……………. Most Significant Bit (MSB).”
4.4.3 The “Byte Count” Field

The “Byte count” field in Modbus messages specifies how many “8-bit data items” are
being transferred in the data section of the message.
In RTU mode, this value is the same as the actual count of bytes in the data section of
the message.
In ASCII mode, this value is one-half of the actual count of ASCII characters or bytes
in the data section of the message.
4.4.4 Register Address Spacing

By default consecutive register addresses in FGM 160 are spaced by one (ref. FGM
160 Modbus register map for DCS port, section 4.3). Default configuration of the FGM
160 is: “Register spacing” = 1 (RS=1, ref. Tables in section 4.3).
This is sufficient if the DCS system treats the FGM 160 Modbus registers as 32 bits
registers (“Daniel Option”, “Register Size” = 32 bits).
But if the DCS system treats the FGM 160 Modbus registers as 16 bits registers
(“Register Size” = 16 bits, Modicon Option), this may lead to a register overlap
problem internal in the DCS memory. The reason for this is that each 32 bits register
in FGM 160, will be read as two consecutive 16 bits registers by the DCS system, and
therefore occupy twice as many addresses internal in the DCS system as in the FGM
160 register map.
One way around this problem is to configure the FGM 160 to have all Modbus register
addresses spaced by two. This can be done by configuring the FGM 160 for: “Register
spacing” = 2 (RS=2, ref. Tables in section 4.3).
If the “Register spacing” is set to 2, the correct Modbus addresses can be obtained
from column “RS=2” in the register address map, section 4.3.
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5. Number Representation
5.1 Single Precision Floating-Point Format
All Modbus register values in the FGM 160 are represented as 32-bit floating-point
values according to the IEEE 754 format.
SEEEEEEE EMMMMMMM MMMMMMMM MMMMMMMM
S = signbit; ( 0 = positive, 1 = negative.)
EEEEEEEE = the binary exponent + 127 decimal
MMMM......M = mantissa bits. An implicit binary point is placed in front of the

first M so that the actual value of the mantissa is less than 1.0.
The value 0.0 is represented with all bits 0.
The value of a binary represented number is
((-1)S) * (2(EEEEEEEE - 127)) * (1.0 + mantissa)
Example:
The value 20.0 = (24) * (1.0 + 0.25)
Binary representation gives:
01000001 10100000 00000000 00000000 Binary
or
41 A0 00 00 Hex
----------------------
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6. Examples
6.1 Function Code 3, Read registers
(default configuration : « Register size » = 32-bit, byte ordering = DCBA)
Example: Read two (32 bits) registers starting at addr. 1010 (03F2hex):
Request:
(MSB) (LSB)
: E0 03 03 F2 00 02 XX <CR><LF>
Reply:
Modbus Slave Function Byte Data1 Data1 Data1 Data1 Data2 Data2 Data2 Data2 Check M o d b u s
ASCII addr. code count (MSB) (LSB) (MSB) (LSB) sum ASCII
only only
: E0 03 08 00 00 00 00 41 20 00 00 XX <CR><LF>
Interpretation of reply: Reg. addr. 1010 (03F2hex) = 0.0

Reg. addr. 1011 (03F3hex) = 10.0
(the IEEE 754 representation of 10.0 is: 41200000hex)
6.2 Function Code 16, Write to registers
(default configuration : « Register size » = 32-bit, byte ordering = DCBA)
Example: Set the value of registers addr. 1031 (0407hex) to 10.0:

(the IEEE 754 representation of 10.0 is: 41200000hex)
Request:
Modbus Slave Function Start reg. Start reg. No. of Regs. No. of Regs. Byte count Data Data Data Data Chk. Modbus
ASCII addr. code (MSB) (LSB) (MSB) (LSB) (MSB) (LSB) sum ASCII
only only
: E0 10 04 07 00 01 04 41 20 00 00 XX <CR><
LF>
Reply:
Modbus Slave Function Start reg. Start reg. No. of Regs. No. of Regs. Chk. Modbus
ASCII addr. code (MSB) (LSB) (MSB) (LSB) sum ASCII
only only
: E0 10 04 07 00 01 XX <CR><LF>
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6.3 Function Code 8; Diagnostics

6.3.1 Sub-function 0 (Return Query Data)
Note that only sub-function 0 is implemented in FGM 160.
Example: Loopback test (sub-function 0)
Request:
Modbus Slave Function Sub-func. Sub-func. Test Data Test Data Check Modbus
ASCII address code code code (MSB) (LSB) Sum ASCII only
only (MSB) (LSB)
: E0 08 00 00 00 AA XX <CR><LF>
Reply:
Modbus Slave Function Sub-func. Sub-func. Test Data Test Data Check Modbus
ASCII address code code code (MSB) (LSB) Sum ASCII only
only (MSB) (LSB)
: E0 08 00 00 00 AA XX <CR><LF>
7. Exception responses
Different exception responses are implemented in the FGM 160. Some of these
exceptions will not occur under normal operation, but the error codes can be useful in
a development phase when new software is tested out. In exception response
messages, the Modbus slave (FGM 160) sets the MSBit of the Function Code to 1. This
makes the Function Code value in an exception response exactly 80hex higher than the
value would be for a normal response.
If the FGM 160 receives a request, but detects a communication error (parity, LRC,
CRC etc.), no response is returned. The DCS system will then eventually process a
timeout condition.
7.1 Standard Modbus Exception Codes
CODE NAME DESCRIPTION

ILLEGAL
1 Illegal function code for this slave.
FUNCTION
The data address is not an allowable address for this slave.
ILLEGAL DATA
2 More specifically; the combination of start address and no. of
ADDDRESS
registers is invalid.
The value contained in the query data field is not allowable for
this slave *).
More specifically;
ILLEGAL DATA
3 Function Code 3: No. of registers in request is an illegal value.
VALUE
Function Code 8: Value in the data field of the request is illegal.
Function Code 16: No. of registers in request is an illegal value,
or “Byte count” value does not match the “No.
of registers”.
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*)
: It specifically does NOT mean that a data item submitted for storage in a register
has a value outside the expectation (valid data range) of the application program,
since the Modbus protocol is unaware of the significance of any particular value of
any particular register.
7.2 Fluenta Defined Exception Code
CODE NAME DESCRIPTION

Register value submitted for storage in a register
ILLEGAL REGISTER
128 has a value outside the expectation (valid data
VALUE
range) of the FGM 160.
Example: Illegal data address in request (addr. 15000 (3A98hex)
Request:
Modbus Sl ave Function D a t a D a t a No. of No. of Check Modbus
ASCII address code Start reg. Start reg. Regs. Regs. Sum ASCII only
only (MSB) (LSB) (MSB) (LSB)
: E0 03 3A 98 00 02 XX <CR><LF>
Reply:
Modbus Slave Function Exception code Check Modbus
ASCII address code Sum ASCII only
only
: E0 83 02 XX <CR><LF>
8. Physical Layer
The Modbus electrical interface at FGM 160 is in accordance with EIA/TIA-485 (also
known as RS485 standard). This standard allows point to point and multipoint
systems, in a “two-wire” or “four-wire” configuration.
8.1 RS422 Compatible Master Node (DCS)

The electrical characteristics for RS485 are specified such that they cover
requirements of RS422.
This allows RS485 compliant drivers/receivers to be used in most RS422 compliant
applications, but the reverse is not necessarily true.
As the RS422 interface require a dedicated pair of wires for each signal, a transmit
pair and a receive pair, this compatibility is only applicable in four-wire configurations.
Four-wire systems often use an RS422 master (the driver is always enabled) and
RS485 slaves to reduce system complexity.
In four-wire configuration, the FGM 160 accepts an RS422 master (DCS system).
72.120.606/D Page 142 of 211

8.2 Two-Wire Configuration (default configuration)

In two-wire configuration, the transmit and receive signals share a single pair of wires
for half-duplex communications. In fact a third conductor must also interconnect all
the devices of the 2W bus: the common conductor.
To avoid conflicts on the communication line, only one driver is allowed to transmit on
the line at any time.
Figure 68 – General 2-Wire Topology.
2-Wire Modbus Circuits Definition:
Signal on Master EIA/TIA-

(DCS) Signal on Slave
485 Description
Name FGM 160
Name Type
Inverted signal
A(-) Out/in A DCS-T- / DCS-R-
(VA>VB » “0”)
Non-inverted signal
B(+) Out/in B DCS-T+ / DCS-R+
(VA<VB » “1”)
Common Common Signal GND DCS-GND Common conductor
72.120.606/D Page 143 of 211

8.3 Four-Wire Configuration

In four-wire configuration, the transmit and receive signals use separate pairs of wires
for possible full-duplex communication. In fact a fifth conductor must also
interconnect all the devices of the 4W bus: the common conductor.
To avoid conflicts on the communication line in “Multipoint” systems, only one driver is
allowed to transmit on the line at any time. “Multipoint“ system is defined as system
with more than one slave device driver(i.e. systems with one master and two or more
slaves).

(DCS) Signal on Slave
485 Description
FGM 160
Name Type Name
T-A(-) Out A DCS-R- Inverted signal (VA>VB » “0”)
T-B(+) Out B DCS-R+ Non-inverted signal (VA<VB » “1”)
R-A(-) In A’ DCS-T- Inverted signal (VA>VB » “0”)
R-B(+) In B’ DCS-T+ Non-inverted signal (VA<VB » “1”)
Common Common Signal GND DCS-GND Common conductor
The 4-W cabling must cross the two pairs of the bus between the master (DCS) and
the slave (FGM 160). That means that the Tx lines from the master must be
connected to the Rx terminals of the slave (FGM 160), and vice versa.
72.120.606/D Page 144 of 211

8.4 Cable Specifications

The Modbus Serial Line Cable must be shielded. At one end of each cable its shield
must be connected to protective ground.
A 2-wire system must use a balanced pair and a third conductor for the Common
(signal GND).
An optionally 4-wire system must use two balanced pair and a third conductor for the
Common (signal GND).
Wire Gauge:
Wire gauge must be chosen sufficiently wide to permit the chosen combination of
baud rate and cable length. AWG24 (0.22 mm2) is normally sufficient.
Characteristic Impedance:
A value higher than 100 Ω may be preferred, especially for 19200 and higher baud
rates. Recommended characteristic impedance is: 120 Ω.
Shunt Capacitance (pF/ft):

One of the factors limiting total cable length is the capacitive load.
Systems with long cable lengths benefit from using low capacitance cable (<16pF/ft).
Cable length:
The end to end length of the Modbus communication cable must be limited.
The maximum length depends on the baud rate, the cable (Gauge, Capacitance or
Characteristic Impedance), the number of loads on the daisy chain, and the network
configuration (2-wire or 4-wire).
For a maximum 9600 Baud Rate and AWG26 (or wider) gauge, the maximum length is
app. 1000m. (AWG26 = app. 0.14 mm2)
Grounding:
The “Common” conductor (signal GND) must be connected directly to protective
ground, preferably at one point only for the entire bus. Generally this point is close to
the master device (DCS system).
Line termination:
Line terminations may be required for high baud rates and long distance.
If line terminations are required, termination resistors should be placed only at the
extreme ends of the communication line(s).
The value of the termination resistors should match the characteristic impedance of
the communication line. Typically value is: 120 Ω (should not be < 90 Ω).
Line Polarization:
The FGM 160 does not need any line polarization resistors (pull–up/pull-down
resistors).
The RS485 receiver (DCS Modbus receiver) at FGM 160, feature fail-safe circuitry
which guarantees a logic-high receiver output when the receiver inputs are open or
shorted. This means that the receiver output will be a logic high (passive level) if all
transmitters on a transmission line are disabled (high impedance).
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8.5 Visual diagnostic

If the FGM 160 is equipped with a display (optional), the Modbus communication
status may be observed by one of the LEDs beneath the display area (Communication
LED). Another LED indicates power applied to the FGM 160 (Power LED).
Indication
State Description
(Color)
Comm. LED
Communication Switched ON during frame reception or sending.
(Green)
Comm. LED (Red) Error Flash: Modbus communication fault
Power LED
Device status Switched ON: device powered
(Green)
8.6 RS485 Modbus Connections at FGM 160
Screw terminals are used for Modbus RS485 / RS422 connections in the FGM 160.
Figure 70 4-wire RS 485 interface between the FGM 160 and the DCS system.
72.120.606/D Page 146 of 211

Figure 71 2-wire RS 485 interface between the FGM 160 and the DCS system.
In order to connect FGM 160 to a two-wire physical interface, the following

modifications should be done:
- The “DCS - R-“ terminal and the “DCS - T-“ terminal shall be wired together.
- The “DCS - R+“ terminal and the “DCS - T+“ terminal shall be wired together.
Figure 72 – Connecting devices with 4-Wire interface to a 2-Wire cabling system.
72.120.606/D Page 147 of 211

9. References
1. Modbus Application Protocol Specification V1.1b, (Dec. 28, 2006).
2. Modbus over serial line, Specification and Implementation Guide V1.02, (Dec. 20,
2006).
3. Modicon Modbus Protocol reference Guide, PI-MBUS-300 Rev. J, (June 2006).
4. B&B electronics, Technical Article #11, Cable Selection for RS-422 and RS-485
systems, (January 1999).
5. Linear Technology, LTC2859/LTC2861 datasheet.
72.120.606/D Page 148 of 211

6.3 HART Output Interface Specification
1. Purpose .....................................................................................................151
2.1 Abbreviations:........................................................................................................................ 151
2.2 Definitions: ............................................................................................................................ 151
3.1 HART Physical Layer ............................................................................................................... 151
3.1.1 Multidrop Operation ..................................................................................................... 151
3.1.2 Connection Loop ............................................................................................................ 151
3.1.2.1 Load Resistor .............................................................................................................. 151
3.1.2.2 Cabling ........................................................................................................................ 151
3.1.2.3 Signal Attenuation and Distortion .............................................................................. 152
3.2 HART Data Link Layer............................................................................................................. 152
3.2.1.1 Burst Mode ................................................................................................................. 152
3.2.1.2 Multimaster Operation............................................................................................... 152
3.2.1.3 Data Throughput ........................................................................................................ 152
3.2.1.4 Character Coding ........................................................................................................ 153
3.3 HART Commands (Application Layer).................................................................................... 153
3.4 HART Device Drivers .............................................................................................................. 153
3.4.1 Device Description (DD)................................................................................................. 153
3.4.2 Device Type Manager (DTM) ......................................................................................... 153
4. FGM 160 HART Functionality .........................................................................154
4.1 HART Output Channel............................................................................................................ 154
4.2 HART Compliance .................................................................................................................. 154
4.3 Device Drivers ........................................................................................................................ 154
4.4 Supported HART Commands ................................................................................................. 155
4.5 HART Poll Address ................................................................................................................. 155
4.6 Multidrop Mode .................................................................................................................... 155
4.7 Burst Mode ............................................................................................................................ 155
4.8 HART Output Parameters ...................................................................................................... 156
4.8.1 HART Variable Unit Codes ............................................................................................. 157
4.9 HART Interface Connection ................................................................................................... 157
4.9.1 Active Output (Loop is Powered from FGM 160) .......................................................... 157
4.9.2 Passive Output (Loop is Powered from HART Master/DCS System) ............................. 159
4.9.3 Multidrop Connections .................................................................................................. 160
4.9.4 Galvanic Isolation........................................................................................................... 160
4.9.5 Grounding ...................................................................................................................... 161
4.9.6 Load / Loop Voltage Limitations .................................................................................... 161
4.9.6.1 Active Output Configuration ...................................................................................... 161
4.9.6.2 Passive Output Configuration ..................................................................................... 161
4.9.6.3 Selection Criteria of Load Resistor Value ................................................................... 162
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4.9.7 Cabling ........................................................................................................................... 162

4.9.7.1 Maximum Cable Length .............................................................................................. 163
5. REFERENCES ..............................................................................................164
72.120.606/D Page 150 of 211

1. Purpose
This document describes the communication interface for the HART output channel of
the Fluenta Flare Gas Meter, FGM 160.
2.1 Abbreviations:
FGM Flare Gas Meter
HART Highway Addressable Remote Transducer
2.2 Definitions:
HART A widely used extension to the 4-20 mA analogue signal used in sensor
networks. HART superimposes a 1,200 bits/second digital signal onto the
line that provides bi-directional communications with intelligent devices.
3.1 HART Physical Layer
HART uses a frequency-shift keying to superimpose digital communication at 1200
baud on to the 4 to 20 mA current loop. Two different frequencies are used to
represent binary 1 and 0 (1200 Hz and 2200 Hz respectively).
The average value of the superimposed HART signal is zero, so no d.c. component is
added to the existing 4 to 20 mA signal. Thus the analogue 4 to 20 mA signal may be
used in addition to the HART communication.
However, this is only possible in point to point configuration. In multidrop

configuration the analogue 4 to 20 mA signals from every transmitter would add
together and give a meaningless total current. The analogue 4 to 20 mA signal is
therefore parked at 4 mA in multidrop configuration (this also reduces the total power
requirement).
3.1.1 Multidrop Operation

Up to 15 slave devices can be connected to a single multidrop pair of wires.
Each of the slaves must have a unique address.
3.1.2 Connection Loop
3.1.2.1 Load Resistor

The power supply is almost a short circuit at the HART signalling frequencies, so a
communicating device cannot be connected directly across it. To avoid this problem, a
load resistor must be inserted in the current loop. The communicating device can then
be connected either across the transmitter or across the load resistor.
The HART specification allows load resistors between 230 and 1100 Ω.
3.1.2.2 Cabling
72.120.606/D Page 151 of 211

The field wiring of a HART system should use a screened twisted pair cable.
Preferably individually-screened twisted pairs should be used to avoid possible
crosstalk between pairs.
3.1.2.3 Signal Attenuation and Distortion

Due to relatively low frequencies, the cable attenuation and delay distortion become
moderate. This implies that HART communication can be performed up to a distance
of 1500 meters or more, provided that the RC time constant of the cable and the
connected devices is 65 µsec. or less.
Since the maximum length of the HART communication line (limited by the RC time
constant) is much smaller than the wavelength of the HART signal (app. 120 km), the
practical HART networks don’t act like transmission lines and there is no need for
impedance matched cables or terminations.
The limiting factors are the loop-capacitance and loop–resistance.

The capacitance and resistance in the loop forms a single pole filter with a cut off
frequency of: 1/(2πRC). For long cable lengths (high capacitance) the filter cut-off can
be close to the HART signal frequency. The result of this is a possible distortion of the
HART signal.
To avoid this kind of distortion, the HART specification imposes a minimum cut-off
frequency of 2500 Hz (at 3 dB attenuation), slightly above the highest HART signalling
frequency. A simple resistance-capacitance circuit will meet this requirement if it has
an RC time constant value of 65 µsec. or less.
The loop resistance mainly consists of the loop resistor, but the cable resistance will
also give a contribution. For long cable lengths, the loop capacitance consists mainly
of the cable capacitance. Device capacitance will also contribute a bit, especially in
multidrop networks with several devices connected in parallel. HART specifications
recommend 5000 pF as a maximum value for device shunt capacitance.
3.2 HART Data Link Layer

HART is a half-duplex “master-slave” protocol. This means that each message
transaction is originated by the HART master; the slave (field) device only replies
when it receives a command message addressed to it.
3.2.1.1 Burst Mode

To achieve a higher data rate, a field device may implement an optional “burst mode”.
When switched into this mode the field device repeatedly sends a data message back
to the master.
3.2.1.2 Multimaster Operation

The HART protocol allows for two active masters in a system, one “primary” and one
“secondary”. Usually, the primary master would be the control system and the
secondary master would be for instance a handheld communicator. The two masters
have different addresses, so each can positively identify replies to its own command.
After each transaction is completed, the master should pause for a short time before
sending another command, to allow an opportunity for the other master to break in if
it wishes.
3.2.1.3 Data Throughput

Typical message lengths allow for maximum two transactions per second.
72.120.606/D Page 152 of 211

In burst mode more than three messages can be transmitted per second.
In multidrop networks, data throughput remains the same as for point-to-point

configuration (max. app. 2 transactions per second). However, latency increases and
is proportional to the number of devices in the network.
Example: in a multidrop network with 4 devices, the latency will be app. 2 seconds
(i.e. the update rate for each device is app. 2 sec.).
3.2.1.4 Character Coding

Character format: 1200 baud, 8 data bits, odd parity, 1 stop bit.
3.3 HART Commands (Application Layer)

HART commands are defined in three groups: “universal”, “common-practice” and
“device-specific”.
“Universal commands” provide functions which are implemented in all HART compliant
field devices.
“Common-practice commands” provide functions common to many field devices, but

not all.
“Device-specific commands” provide functions which are more or less unique to a

particular field device.
3.4 HART Device Drivers

3.4.1 Device Description (DD)
A Device Description (DD) is a device driver for specific features and functions of a
HART device.
A Device Description (DD) is an electronic data file prepared in accordance with

Device Description Language specifications that describes specific features and
functions of a device including details of menus and graphic features to be used by
host applications to access all parameters and data in the corresponding device.
The DD identifies which common practice commands are supported as well as the
format and structure of all device-specific commands.
A DD is an optional element of the HART communication technology and is not

required to communicate with a HART device. DD are mostly used for device set-up
and not required for routine device communication.
3.4.2 Device Type Manager (DTM)

A Device Type Manager (DTM) is the device driver for the FDT standard.
FDT (Field Device Tool) is an interface specification that standardizes the data
exchange between field devices and the system level (FDT frame application).
72.120.606/D Page 153 of 211

FDT frame applications can be device configuration tools, control systems, operator
consoles or asset management tools etc.
Examples of FDT frame applications are: PACTware, FieldCare (E+H), ControlBuilderF

(ABB), fdtContainer (M&M Software).
FDT is communication independent and can be used with any communication protocol
(e.g. HART, Modbus, Profibus, Foundation Fieldbus, etc.).
An appropriate DTM for every instrument of every supplier is not yet available. If no
specific DTM exists for a HART-capable field device, a generic HART DTM can be used.
The universal and common-practice commands based on the HART specification that
are used by most HART devices on the market are supported by the generic DTM.
Generic HART DTM is available from various companies (e.g. ICS GmbH).
4. FGM 160 HART Functionality

4.1 HART Output Channel
One of the current loop outputs of FGM 160 can be configured and used for HART
communication. The other current loop outputs have no HART functionality.
The HART output channel can be configured as a passive output (external loop power)
or as an active output (powered from FGM 160).
4.2 HART Compliance

At the moment, the FGM 160 only supports a limited selection of the HART universal
command and is therefore not fully HART compliant.
No common-practice, or device-specific commands are supported by the FGM 160.
4.3 Device Drivers

As no device-specific commands are supported by the FGM 160, there is no need for a
special device driver in order to communicate with the device.
Therefore no specific Device Description (DD) or Device Type Manager (DTM) is

available for the FGM 160.
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4.4 Supported HART Commands
The following HART universal commands are supported by FGM 160:
Table 4 - Supported HART commands

HART command # Function
0 Read unique identifier.
1 Read primary variable.
2 Read current and percent of range.
3 Read current and four (predefined) dynamic variables.
12 Read message.
13 Read tag, descriptor, and date.
16 Read final assembly number.
NOTE:
The FGM 160 does not support any HART write commands and it is therefore not
possible to configure the device via the HART interface.
For configuration of the FGM 160, the FGM 160 Operator & Service Console must be
used. This software communicates with the FGM 160 through the dedicated RS-485
service port.
4.5 HART Poll Address

The FGM 160 can be set up with a HART poll address in the range 0 to 15.
The default HART poll address for the FGM 160 is:
1 (Optional addresses: 0 – 15).
4.6 Multidrop Mode

The FGM 160 supports multidrop mode.
If the HART poll address is set to a value other than 0, the analogue current loop
signal is set to a fixed value of 4 mA. The device is then parked and enabled for
multidrop operation.
If the HART poll address is set to 0, analogue 4 to 20 mA signal may be used in

addition to the HART communication.
4.7 Burst Mode

The FGM 160 does not support the optional “burst mode” operation.
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4.8 HART Output Parameters

Parameters available as HART variables are listed in the table below.
This table contains a limited selection of the FGM 160 DCS Modbus registers (available
through the RS-485 DCS port).
Any of these parameters can be selected for HART Primary variable (PV), Secondary
variable (SV), Third variable (TV) and Fourth variable (FV).
The selected parameters will be available for read-out through HART command 1 (PV)
and HART command 3 (PV, SV, TV and FV).
For configuration of the HART output parameters, the FGM 160 Operator & Service
Console must be used.
Table 5 - HART Output parameters.

Modbus
Parameter Def. unit Min Max reg. no:
Volume Flowrate at Reference Conditions Sm3/h *) -- -- 8
Volume Flowrate at Actual Conditions m3/h *) -- -- 9
Mass Flowrate kg/h *) -- -- 10
*)
Gas Flow Velocity m/s -- -- 11
*)
Gas Flow Velocity w/Threshold m/s -- -- 12
*)
Gas Flow Velocity, uncompensated m/s -- -- 13
*)
Velocity of Sound m/s -- -- 20
Gas Density kg/m3 -- -- 21
Molecular Weight g -- -- 22
Alarm Status -- 0 23
*)
Pressure bar A 30
*)
Temperature °C 31
1) *)
Pressure, HART Transmitter 1 bar A 32
2) *)
Pressure, HART Transmitter 2 bar A 33
1) *)
Temperature, HART Transmitter 1 °C 34
2) *)
Temperature, HART Transmitter 2 °C 35
Totalized Volume at Reference Conditions Sm3 *)

0 999999 40
Totalized Volume at Actual Conditions m3 *)
0 999999 41
*)
Totalized Mass kg 0 999999 42
Totalized Vol. at Ref. Cond. Overflow Count 1000000 0 1000000 43
Totalized Vol. at Act. Cond. Overflow Count 1000000 0 1000000 44
Totalized Mass Overflow Count 1000000 0 1000000 45
Last 24h Accumulated Volume at Ref. Cond. Sm3 *)

0 -- 50
Last 24h Accumulated Volume at Act. Cond. m3 *)
0 -- 51
*)
Last 24h Accumulated Mass kg 0 -- 52
Transit Time % Used, Upstream % 0 100 114

Transit Time % Used, Downstream % 0 100 115
*)
Internal Temperature, Electronics °C 125
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Notes:
1)
: Data from HART Transmitters is only applicable for FGM 160 systems configured
for HART Pressure and Temperature transmitters.
2)
: Data from HART Transmitter 2 is only applicable for FGM 160 systems
configured for double HART transmitters.
*)
: Optional units:
Table 6 – HART output parameter, optional units.
Parameter Optional units
MMCFD (Million Cubic Foot per Day),
Volume flowrate
MMSCFD (Million Standard Cubic Foot per Day)
Mass flowrate lbs/h
Velocity ft/s
Pressure kPa A, psi A, kg/cm2 Abs
Temperature °F
Acc./totalized volume MMCF, MMSCF
Acc./totalized mass lbs
For configuration of HART output parameters units, the FGM 160 Operator &
Service Console must be used.
All HART variable values will be transmitted as floating-point numbers, 32-bit single
precision (IEEE 754), according to HART specification HCF_SPEC-127.
4.8.1 HART Variable Unit Codes

The HART variable unit code(s) is included in the reply of HART command 1 (read
primary variable) and HART command 3 (read current and four dynamic variables).
The following HART unit codes are implemented in FGM 160:
Table 7 - HART unit codes.
Engineering unit HART unit code
4.9 HART m3/h 19 Interface
*)
MMCFD 242 Connection
kg/h 75
4.9.1 Active lbs/h 82 Output (Loop is
Powered m/s 21 from FGM 160)
ft/s 20
kg/m3 92
g 60
bar A 7
kPa A 12
psi A 6
kg/cm2 Abs 10
°C 32
°F 33
m3 43
*)
MMCF 243
kg 61
lbs 63 Note:
*)
% 57 : Unit codes 242 and 243 are
manufacturer specific definitions.
-- (none) 251
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Figure 73 HART connection with active output configuration.
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4.9.2 Passive Output (Loop is Powered from HART Master/DCS System)
Figure 74 HART output with passive output configuration.
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4.9.3 Multidrop Connections
FGM 160 FGM 160 FGM 160

Poll addr.1 Poll addr.2 Poll addr.3
In multidrop mode up to 15 devices (FGM 160 or other

HART devices) can be connected in parallel.
Shielded twisted pair cable.
Be aware of the increased latency in multidrop

networks. Latency is proportional to the number of
devices in the network.
Example: 4 devices in a multidrop network give a

latency of app. 2 sec. (i.e. an update rate of 2 sec. for
each device)
Passive or active output may be used in multidrop

configuration.
Connect screen at one end only.

Normally at the master end.
÷ Power
Active output
Passive output
connections
connections
+ supply
HART Master HART Master
Figure 75 HART multipoint connection (multidrop).
4.9.4 Galvanic Isolation
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The HART output terminals (as well as the other current loop outputs) are galvanic
isolated from the rest of the FGM 160 electronics.
However, the individual current loop outputs are not isolated with regards to each
other. (i.e. the HART output terminals are not isolated from the other current loop
outputs of the FGM 160).
4.9.5 Grounding
To prevent interference by external signals, it is important to ground the system
properly.
The cable screen must be connected to ground at one point only. This single ground
point will normally be at or near the primary master (for example, the control
system). The screen is left open at the other end (normally field instrument end) to
avoid the conduction of ground currents.
The signal loop should be grounded at one point or may be ungrounded (floating) if
electrical noise is minimal. If the signal loop is grounded, the negative signal wire
should be connected to ground, preferably at the same point as the cable screen.
Special precautions for FGM 160:

When multiple current loop outputs are used in active output configuration, the signal
loops must NOT be grounded, as this will cause erroneous readings of all current loop
outputs (ref. note in Figure 73, optional ground connection).
This is however not a problem in;

- passive output configuration and,
- active output configuration with only one current loop in use.
4.9.6 Load / Loop Voltage Limitations

HART specification requires a loop resistance between 230 and 1100 Ω.
4.9.6.1 Active Output Configuration

In active output configuration the loop voltage is 30 V.
According to Figure 76, the load limitation at 30 V is min. 230 Ω and max. 1100 Ω.
4.9.6.2 Passive Output Configuration

In passive output configuration the load limitation is dependent upon the external loop
voltage.
Loop voltage: min. 7.6 V, max. 50 V

Load resistor: U = 25 to 33 V: Rload: min. 230 Ω, max. 1100 Ω.
U < 25 V: Rload: min. 230 Ω, max.: (U-3 V) x 50.
U > 32.6 V: Rload: max. 1100 Ω, min.: (U-28 V) x 50.
72.120.606/D Page 161 of 211

1200.0
1100.0
1000.0
900.0
Load resistor [Ω]
800.0
700.0
HART operating range
600.0
500.0
400.0
300.0
200.0
5 7.6 10 15 20 25 30 32.6 35 40 45 50
Loop voltage [V]
Figure 76 Load / voltage limitations.
Table 8 Min. /max. load resistor value at typical loop voltages.

Loop voltage Rload min. Rload max.
12 V 230 Ω 450 Ω
24 V 230 Ω 1050 Ω
36 V 400 Ω 1100 Ω
48 V 1000 Ω 1100 Ω
4.9.6.3 Selection Criteria of Load Resistor Value

- Cable length: To achieve maximum useful cable length, select the smallest
allowable load resistor value according to Figure 76.
- Signal level: The load resistor value may be increased if the signal level of slave
response is low. (should be min. 120 mV p-p).
- Loop voltage: For loop voltages above 32.6 V it may be necessary to increase the
load resistor value due to power rating limitations of the FGM 160
current loop outputs (ref. Figure 76).
4.9.7 Cabling
Low capacitance, individually screened, twisted pair cable with min. 0.5 mm2 cross
section (AWG 20) is recommended.
For shorter distances, 0.2 mm2 (AWG 24) twisted pair with common screen can be
used.
72.120.606/D Page 162 of 211

4.9.7.1 Maximum Cable Length

The following rule of thumb can be used to determine the app. maximum loop length:
Max. length = 65 x 106 / (R x C) – (Nx5000+10000)/C

where; R is the total loop resistance in Ω
C is the cable capacitance in pF/m (or nF/km)
N is the number of slaves connected in parallel (multidrop)
A low loop resistor value will help to increase the max. loop length (however, the
lower limit in HART specification is 230 Ω).
Multidrop operation reduces the possible cable length, since the capacitance of the
field devices increases the total C (and the RC time constant).
Example: Point-to-point configuration (one slave device)

Cable: RFOU(i) instr. cable, 0.75 mm2 (115 nF/km, 25 Ω/km)
Load resistor: 270 Ω
Max. cable length ≈ 65 x 106 / ((270+75) x 115) – 15000/115 ≈ 1500 m
Note:
The total loop resistance consists of load resistor + cable resistance (both conductors
in series).
The cable capacitance is the capacitance measured from one conductor to all others
and screen (not between the two conductors of a pair, as commonly quoted).
HART maximum cable length
Belden 3105A 0.35mm2, N=1

2000 RFOU(i) 0.75mm2, N=1
IYOI(c) 0.2mm2, N=1
RFOU(i) 0.75mm2, N=5
1500 IYOI(c) 0.2mm2, N=5
Cable length [m]
RFOU(i) 0.75mm2, N=15

IYOI(c) 0.2mm2, N=15
1000
500
0
230 330 430 530 630 730 830 930 1030 1130
Load resistor [Ω]
Figure 77 HART maximum cable length.
Cable parameters used in Figure 77: RFOU(i) 0.75 mm2: 115 pF/m, 25 Ω/km
IYOI(c) 0.2 mm2: 90 pF/m, 95 Ω/km
Belden 3105A 0.35 mm2: 66 pF/m, 49 Ω/km
72.120.606/D Page 163 of 211

5. REFERENCES
[1] HART Field Communication Protocol, A Technical Overview. (Second Edition).
Romilly Bowden, February 2002.
[2] About HART, By Analog Services, Inc., Part 1: Preliminaries (rev. 2-1-01)
[3] About HART, By Analog Services, Inc., Part 2: Practical Stuff (rev. 8-9-99)
[4] About HART, By Analog Services, Inc., Part 3: Ponderous Stuff (rev. 8-9-99)
[5] HART Application Guide, HART Communication Foundation (HCF), 2003
[6] What is a Device Description? Romilly Bowden, 1999.
[7] HART Protocol, Data Link Layer Specification, HCF_SPEC-81, rev.7.0
[8] HART Protocol, Command Summary Specification, HCF_SPEC-99, rev.7.0
[9] HART Protocol, Universal Command Specification, HCF_SPEC-127, rev.5.1
[10] HART Protocol, Common Tables, HCF_SPEC-182, rev.7.0
[11] Datasheet, Draka Norsk kabel, RFOU_i_250V_IEC60092-376
[12] Datasheet, Draka Norsk kabel, IYOI(c)_0,5mmØ.e01.doc
[13] Datasheet, Belden, 3105A Multi-Conductor – EIA Industrial RS-485 PLTC/CM,

03-16-2009
72.120.606/D Page 164 of 211

Maintenance Procedure
6.4 Operator Console Description

1. Purpose .....................................................................................................166
2.1 Abbreviations:........................................................................................................................ 166
3. General ......................................................................................................166
3.1 Interface Between FGM 160 and O&SC ................................................................................ 166
3.1.1 Two-Wire Configuration ................................................................................................ 166
3.1.2 Four-Wire Configuration................................................................................................ 167
3.1.3 Cable Specifications ....................................................................................................... 168
3.1.4 RS 485 Connection at FGM 160 ..................................................................................... 169
3.2 Remote Operation of the O&SC ............................................................................................ 171
3.2.1 Remote Operation with RS485 / TCP/IP Converter ....................................................... 171
3.2.2 Remote Operation with Remote Control Software ....................................................... 171
3.3 General Layout ...................................................................................................................... 172
3.3.1 O&SC Menus .................................................................................................................. 173
3.4 Live Data Window .................................................................................................................. 174
3.5 Graph Bar Window ................................................................................................................ 175
3.5.1 Graph Config Window ................................................................................................... 176
3.6 Log ......................................................................................................................................... 178
3.6.1 Alarm Log ....................................................................................................................... 178
3.6.2 Log Data ......................................................................................................................... 178
3.7 Config Window ...................................................................................................................... 179
3.7.1 Config Main Page ........................................................................................................... 179
3.7.2 Communication Settings................................................................................................ 182
3.7.3 Input Signal Configuration ............................................................................................. 182
3.7.4 Output Signal Configuration .......................................................................................... 185
3.7.5 Alarm Limits Configuration ............................................................................................ 186
3.8 Transit Time Measurements Window ................................................................................... 187
3.9 Help About Window .............................................................................................................. 189
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1. Purpose
The purpose of this document is to give a detailed description of how the Operator &
Service Console (O&SC) operates. This document will only cover the section related to
the Operator interface, as the Service section applies to Fluenta support personnel
only. The interface between the FGM 160 and the O&SC will be described, with local
and remote operation. Further, the menu and windows based O&SC software will be
outlined with detailed description of each program window.
2.1 Abbreviations:
FGM Flare Gas Meter
O&SC Operator & Service Console
3. General
3.1 Interface Between FGM 160 and O&SC
The O&SC can be interfaced to the FGM 160 either by 2- or 4-wire RS 485 or 4-wire
RS 422. The communication protocol setup is fixed at:
Baudrate: 38400
Data bits: 8
Stop bits: 2
Parity: None
Protocol: Modbus RTU
Figure 1 shows the Fluenta AS Flare Gas Meter (FGM 160) terminals. The only
terminals that are of interest in this procedure are terminals 16-20, as they are the
terminals that provide a connection to the operator console. There are two possible
connections that can be made to these terminals, either a two or four wire RS485
cable. These connections are explained in detail in the following sections.
3.1.1 Two-Wire Configuration

In two-wire configuration, the transmit and receive signals share a single pair of wires
for half-duplex communications. In fact a third conductor must also interconnect all
the devices of the 2W bus: the common conductor.
To avoid conflicts on the communication line, only one driver is allowed to transmit on
the line at any time.
72.120.606/D Page 166 of 211


(O&SC) Signal on Slave
485 Description
Name FGM 160
Name Type
The line is negative

Serv. Port T- /
A(-) Out/in A (compared to B) when the
Serv. Port R-
line is idle (i.e. data is 1).
The line is positive

Serv. Port T+ /
B(+) Out/in B (compared to A) when the
Serv. Port R+
line is idle (i.e. data is 1).
Common Common Signal GND Serv. Port GND Common conductor
3.1.2 Four-Wire Configuration

In four-wire configuration, the transmit and receive signals use separate pairs of wires
for possible full-duplex communication. In fact a fifth conductor must also
interconnect all the devices of the 4W bus: the common conductor.
To avoid conflicts on the communication line in “Multipoint” systems, only one driver is
allowed to transmit on the line at any time. “Multipoint“ system is defined as system
with more than one slave device driver (i.e. systems with one master and two or more
slaves).
72.120.606/D Page 167 of 211


(O&SC) Signal on Slave
485 Description
Name FGM 160
Name Type
The line is negative (compared
T-A(-) Out A Serv. Port R- to B) when the line is idle (i.e.
data is 1).
The line is positive (compared
T-B(+) Out B Serv. Port R+ to A) when the line is idle (i.e.
data is 1).
The line is negative (compared
R-A(-) In A’ Serv. Port T- to B’) when the line is idle (i.e.
data is 1).
The line is positive (compared
R-B(+) In B’ Serv. Port T+ to A’) when the line is idle (i.e.
data is 1).
Common Common Signal GND Serv. Port GND Common conductor
The 4-W cabling must cross the two pairs of the bus between the master (O&SC) and
the slave (FGM 160). That means that the Tx lines from the master must be
connected to the Rx terminals of the slave (FGM 160), and vice versa.
3.1.3 Cable Specifications

The Modbus Serial Line Cable must be shielded. At one end of each cable its shield
must be connected to protective ground.
A 2-wire system must use a balanced pair and a third conductor for the Common
(signal GND).
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An optionally 4-wire system must use two balanced pair and a third conductor for the
Common (signal GND).
Wire Gauge:
Wire gauge must be chosen sufficiently wide to permit the chosen combination of
baud rate and cable length. AWG24 (0.22 mm2) is normally sufficient.
Cable length:
The end to end length of the Modbus communication cable must be limited.
The maximum length depends on the baud rate, the cable (Gauge, Capacitance or
Characteristic Impedance), the number of loads on the daisy chain, and the network
configuration (2-wire or 4-wire).
Grounding:
The “Common” conductor (signal GND) must be connected directly to protective
ground, preferably at one point only for the entire bus. Generally this point is close to
the master device (DCS system).
Line termination:
Line terminations may be required for high baud rates and long distance.
If line terminations are required, termination resistors should be placed only at the
extreme ends of the communication line(s).
The line termination resistors shall be selected according to the cables characteristic
impedance; typical 120 Ω. Non-terminated or wrong terminated cables may cause
severe communication problems.
Line Polarization:
The FGM 160 does not need any line polarization resistors (pull–up/pull-down
resistors).
The RS485 receiver (O&SC) at FGM 160, feature fail-safe circuitry which guarantees a
logic-high receiver output when the receiver inputs are open or shorted. This means
that the receiver output will be a logic high (passive level) if all transmitters on a
transmission line are disabled (high impedance).
3.1.4 RS 485 Connection at FGM 160

The connection below illustrates the 4-wire RS485 connection. Usually either an
RS485 to USB or an RS485 to RS232 converter is required to interface to the
computer with the Operator & Service Console software installed.
72.120.606/D Page 169 of 211

Figure 80 4-wire RS 485 interface between the FGM 160 and the O&SC.
The connection below illustrates the 2-wire RS485 connection. Usually either an
RS485 to USB or an RS485 to RS232 converter is required to interface to the
computer with the Operator & Service Console software installed.
Figure 81 2-wire RS 485 interface between the FGM 160 and the O&SC, with
jumpers between T- and R-, and between T+ and R+.
72.120.606/D Page 170 of 211

In order to connect FGM 160 to a two-wire physical interface, the following

modifications should be done:
- The “Serv. Port - R-“ terminal and the “Serv. Port - T-“ terminal shall be wired
together.
- The “Serv. Port - R+“ terminal and the “Serv. Port - T+“ terminal shall be wired
together.
If remote control of the FGM 160 is requested, a RS485 - TCP/IP converter can be
used in order to access the computer with the O&SC software installed.
Figure 82 – Connecting devices with 4-Wire interface to a 2-Wire cabling system.
3.2 Remote Operation of the O&SC

The FGM 160 can be remotely operated either through a RS 485 / TCP/IP converter,
or through Remote Control software. The two configurations will both allow for remote
operation of the O&SC, but with minor differences:
3.2.1 Remote Operation with RS485 / TCP/IP Converter

Remote operation with RS485 / TCP/IP converter requires the O&SC software to be
installed at the remote computer, ref. Figure 83. The operator will access the FGM 160
as if he/she operated the meter locally at site. All functions available in the O&SC are
available at the remote computer. If the operator has several O&SC licenses, any of
the computers with a valid license and O&SC software can access a specific FGM 160,
with a known TCP/IP address.
3.2.2 Remote Operation with Remote Control Software

The Remote Control software allows remote operation of the FGM 160 without the
O&SC software installed on more than one computer (at site). A special Remote
Control software is installed both at the computer at site (the HOST) and at the
remote computer (the GUEST). The remote computer (the GUEST) can not access the
local computer (the HOST) unless the HOST grants the GUEST access. Thus, the
72.120.606/D Page 171 of 211

operator will have full access control of the HOST computer, allowing only authorized
users to access the local (HOST) computer.
By using the Remote Control software, the remote computer (the GUEST) will take
control of the local computer (the HOST). Thus, the GUEST will run the O&SC as if the
software was installed at the GUEST computer.
HAZARDOUS AREA SAFE AREA REMOTE
O&SC
O&SC
Remote
Control
FGM 160 HOST Remote
Control
RS 485
GUEST
RS 485 - TCP/IP
FGM 160 converter O&SC
Figure 83 Remote operation of the O&SC, with two different configurations; either
by RS485 / TCP/IP interface, or through Remote Control software.
3.3 General Layout

The Main Window is shown below in Figure 4. There are several windows that can
be displayed in the Main View Window, but the three operator windows are shown
here. These are the windows that normally are visible when monitoring the meter’s
operation. The other windows are used for setup and formatting functions. These
three windows can be accessed via the View menu, and are the Graph Bar, Live
Data and Log windows. By double clicking on the windows heading bar it is possible
to un-dock it from the main window, dragging it back into the main window’s view
area will re-dock it.
To avoid docking a window, hold the Ctrl-key down while dragging.
72.120.606/D Page 172 of 211

Figure 84 O&SC general layout, with Graph Bar, Live Data and Log windows.
3.3.1 O&SC Menus

The O&SC menus are displayed below. The menu items shown below will be covered
in this document. The icons in the bottom menu bar allow the user to change the
appearance of the program.
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Figure 85 The O&SC menus overview, with the “File”, “Edit”, “View”, “Polling
mode”, “Tools” and “Help” items outlined.
3.4 Live Data Window

The Live Data window can be activated by choosing the View → Live Data pop-up
menu from the main window. The Live Data window shows the Current System data,
along with the volume and mass flow rates. Further, totalized values for volume and
mass are displayed. These values are non-resetable, and display the total values since
the system was put in operation. The temperature, pressure, flow velocity, velocity of
sound, and density are also presented in this window. The Data Time Tag is the actual
time the present displayed data set was measured or calculated.
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Figure 86 The Live Data window is activated through the View → Live data menu.
The Live Data window is a read-only information window, with
information on the current system and updated (live) process data.
3.5 Graph Bar Window

The Graph Bar window displays up to four different parameters as graph data. Thus,
the operator can view selected parameters as trend data for easy monitoring of
process variations. The graph parameters can be selected from:
Ø Mass Flow
Ø Volume Flow act. Vol. – The volume flow at actual (line) conditions
Ø Volume Flow std. Vol. – The volume flow at standard conditions
Ø Gas Flow Velocity
Ø Pressure
Ø Temperature
Ø Density
Ø Sound Velocity
Ø CWUpAve – Average transit time in the Upstream direction
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Ø CWDownAve – Average transit time in the Downstream direction

Ø Unused
If it is desired to have less than four parameters shown on the graph, select the
“Unused” option. The legend at the top of the Graph Bar window shows which items
are currently being displayed.
Figure 87 The Graph Bar window, with up to four different process parameters
displayed as graph data.
3.5.1 Graph Config Window
By pressing the button the Graph Config window opens. This allows
the operator to configure the look of the graph as well as the scale. The trend
diagram area allows the operator to choose the Y Scale and the Time Scale. The Y
Scale can either be set to automatic by checking the checkbox next to the field
Autoscale and setting the minimum range, or stated explicitly by entering the
minimum and maximum values for the parameters. The Bar Plot area allows the
operator to set the maximum value, the warning, and whether to plot Mass Flow or
Volume Flow.
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Figure 88 The Graph Bar - Graph Config window. Each graph bar can be
individually configured with either autoscale or defined minimum and
maximum range. If autoscale is selected, a minimum range (span) can
be set.
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3.6 Log
3.6.1 Alarm Log
By selecting the Log option from the View menu item from the Main Window. The
window comes up showing the Log Main Page tab which lists the alarms that have
occurred. There are two options when it comes to copying the Alarm Log. The first is
to copy it to the clipboard. This enables the operator to paste the data wherever
necessary. The second is to copy the alarm log to a file. This saves the Alarm Log as
a text file to a specified location. The last choice in this tab is to clear the alarm log.
Figure 89 The Log – Log Main Page window.
3.6.2 Log Data

The Data tab in the Log window displays the options for what kind of data is logged.
Checking the Log Measured Data checkbox enables data logging, and the Optional
sub category allows the operator to specify a sub-directory to where the data log file
will be saved. The button Set All allows the operator to log all of the parameters that
are available below. The Clear All button unselects all of the options below. This is
useful when only a few options are desired. The Set Default button sets a default set
of parameters to be logged. It is possible to check or uncheck any of the parameters
that are listed.
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Figure 90 The Log - Data window.
3.7 Config Window

3.7.1 Config Main Page
The Config Main Page tab comes up automatically when choosing the View →
Config menu item. The System Configuration section allows the operator to insert
a serial number, specify the system version (Single Ch1, Single Ch2, Dual Path and
Double), as well as insert the start time for the 24 hours Accumulated values.
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Figure 91 The Config – Config Main Page window
The Change Descriptions button opens the System Description dialog box, ref.
Figure 92. This allows the operator to change the information shown in the Live Data
window shown in Section 3.4.
Figure 92 The Config – Config Main Page – Change Description window.
The Real Time Clock section allows the operator to set or get the clock readings from
the flow computer. The Synch with PC button synchronizes the flow computer clock
with the clock in the PC running the Operator and Service Console software.
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The Update button updates (refreshes) the real time clock values based on current
information locally on the O&SC computer. The Calculation Parameters section
allows the operator to set the Flow Velocity Threshold(cut-off), the reference
temperature for standard conditions, and the reference pressure for standard
conditions. The flow velocity threshold is the low flow cut-off limit that can be
implemented upon operator request. Flow values below the cut-off limit will be set to
zero. The reference temperature for standard conditions is default 15.0 °C, and the
reference pressure for standard conditions is default 1.01325 barA.
The Units section allows the operator to switch from SI units to English units. This
changes the units for the DCS Modbus and HART register values.
The Mechanical Parameters section makes it possible to change the physical

parameters of the installation. This should only be necessary during installation and
hook-up.
The Modbus Parameters DCS port section allows the operator to set up the
communication parameters.
The Get Config to Clip Board copies the configurations file to the clip board so that
it can be pasted into an existing document (e.g. configuration file template). The
button Get Config to File saves the system configuration to a text file. The dialog
boxes in Figure 93 illustrate how this is done.
Figure 93 Copying system configuration to the clipboard and saving to a file.
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3.7.2 Communication Settings

In the communication setting tab in the Config Main Page the operator can set up
the Modbus interface on the PC. The Com port can be selected. The Timeout value for
the com port can be altered (Should normally not be altered). And finally the operator
can select the Modbus address. This allows the operator to select to operate one
specific instrument, if multidrop is not used; the slave address should always be 1.
Figure 94 The Config - Communication settings window.
3.7.3 Input Signal Configuration

The Input signal configuration window shown in Figure 95 allows the operator to
configure the Pressure and Temperature input signals to the meter.
Figure 95 The Config - Input signals configuration window, with HART interface
selected for the pressure and temperature input signals.
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The Pressure Processing drop down selection box allows the user to switch between
the HART and the Current Loop as sources for the pressure input.
The Temperature Processing drop down selection box allows the user to switch
between the HART, Current Loop, and RTD as sources for temperature input. The RTD
is integrated in the ultrasonic sensors, and will measure the process temperature
through the ultrasonic sensor walls.
The Current Loop Calibration Pressure and Temperature groups allow the operator to
set the offset and scale for the pressure and temperature inputs, ref. Figure 96.
When selecting the HART interface for the pressure and temperature input signals, the
Input Config must be set to HART. Further the check boxes Enable HART
Temperature/Pressure must be selected (checked), ref. Figure 95.
When selecting the 4-20 mA current loop interface for the pressure and temperature
input signals, the check boxes for Enable CurrentLoop Temperature/Pressure must
also be selected (checked), ref. Figure 96. Enable HART Temperature/Pressure should
NOT be checked in this case.
Figure 96 The Config - Input signals configuration window, with 4-20 mA current
loop interface selected for the pressure and temperature input signals.
The Current Loop Range: Temperature & Pressure groups allow the operator to set the
4-20mA range to the corresponding temperatures and pressures, respectively. It is
important that these ranges match the output ranges of the transmitters. If not, the
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readings of the FGM 160 will not be correct. If HART interface is selected, the settings
for Current Loop Range: Temperature & Pressure will have no effect, as the pressure
and temperature values will be transmitted as digital values.
The 4-20 mA input channels can be calibrated using e.g. a loop calibrator. By using a
first degree curve fitting approach, the offset and scale values can be obtained. The 4-
20 mA input channels of the FGM 160 are calibrated at the Fluenta AS workshop,
ensuring that no calibration should be required during installation and commissioning,
ref. Figure 96.
If no direct interface from the pressure and temperature transmitters has been
established, these process values can be transmitted from the DCS system to the FGM
160 through the DCS Modbus interface. The DCS system must then, as Modbus
master, supply pressure and temperature values to the FGM 160 at regular intervals.
In order to enable the FGM 160 to read pressure and temperature values through the
DCS Modbus interface, the Get Pressure/Temperature from Modbus check boxes must
be selected (checked), ref. Figure 97.
Note:The check boxes are NOT exclusive. Thus, selecting one check box does not
automatically deselect the alternative option check box. Make sure that options
that are not selected, are deselected (NOT checked).
Figure 97 The Config - Input signals configuration window, with DCS Modbus
interface selected for the pressure and temperature input signals.
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3.7.4 Output Signal Configuration

The Config - Output window allows the operator to configure the output from the
flow computer. The group of check boxes labeled Output Enable determines which
output is to be used, ref. Figure 98.
For each of the current loops enabled, the corresponding Current loop X (X being the
number of the current loop 1- 6) must be configured. The drop down box allows the
user to select which parameter will be transmitted at the output. The choices are Std.
Volume flow, Actual Volume flow, Mass flow, Density, Molecular weight, Alarm,
Temperature, Pressure, and Testvalue, ref. Figure 99. The desired parameter must be
selected and the corresponding configuration values to the right must be entered.
If the Enable HART check box is selected, the HART Output (Slave) Config group must
be configured, ref. Figure 98. The Poll address must be entered, and up to four
parameters can be selected. These parameters can be any combination of Flow Std,
Flow Act, Flow Mass, Flow Velocity, Sound Velocity, Density, Pressure and
Temperature.
Figure 98 The Config - Output signal configuration window, with the HART Output
(Slave) Config box outlined. The Poll Address must be selected (1 – 15),
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and up to four predefined process parameters can be selected at the

HART output.
Figure 99 The Config - Output signal configuration window, with the parameters
available at the 4-20 mA current loop outputs outlined.
3.7.5 Alarm Limits Configuration

The Alarm Limits tab in the Config window allows the operator to configure the
alarm settings.
The Sound Velocity has four parameters that must be specified:
1. The Maximum and Minimum which are the upper and lower limits of the sound
velocity before an alarm is generated.
2. The Maximum Sound Velocity jump regarded as an expected process variation.
3. The Historical VOS weight factor which is used in calculating the Historical VOS.
The Flow Velocity has three parameters that must be specified:
1. The Maximum and Minimum which are the upper and lower limits of the flow
velocity before an alarm is generated.
2. The Maximum Change which is the maximum difference between two
consecutive readings before an error is reported.
For the Temperature and Pressure, the Maximum and Minimum alarm values must be
specified. Input values outside the alarm range will generate an alarm.
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Figure 100 The Config - Alarm Limits window, with specified Maximum and
Minimum values for Sound Velocity, Flow Velocity, Temperature and
Pressure.
Based on the specified transducer distance and the max/min values for Sound Velocity
and Flow Velocity, the Maximum and Minimum values for Time-of-Flight (TOF)
Downstream and Upstream are calculated. These values are used internally in the
FGM 160 in order to check the validity of the transit time measurements.
3.8 Transit Time Measurements Window

The Transit Time Measurements Window can be accessed via the View → Transit
Times Measurements menu item. This window allows the operator to view the
measured transit times, both the Chirp transit times, the CW period fraction
measurements, and the (Chirp and CW) combined transit times that are used for the
flow calculations. The CW period fraction value is a counter value corresponding to the
fraction of a CW period, a number between 0 and 15000 (typical), dependent on CW
signal frequency.
Further, the % used of the measured transit times for the flow calculations are
displayed. If all measured transit times are used for the flow calculations, the
numbers should be 100.0. Any erroneous measurements or outliers that are discarded
during the filtering process will reduce the number of % used.
In addition, the gas flow velocities can be viewed, both prior to flow profile
compensation (uncompensated) and after flow profile compensation. Thus, the “raw”
(uncompensated) axial gas flow velocity can be viewed, along with the average axial
gas flow velocity (compensated for flow profile).
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Figure 101 The Transit Time Measurements window, with the Chirp and CW
measurements, the uncompensated and flow profile compensated flow
velocity and velocity of sound, and the % used transit time
measurements.
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3.9 Help About Window

The Help → About window displays the program version of the Operator Console, ref.
Figure 102.
Figure 102 The Help About window, with information on the O&SC software
version.
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7. MAINTENANCE INSTRUCTIONS
7.1 Maintenance Procedure
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7.1 Maintenance Procedure

1. Purpose .....................................................................................................192
2.1 Abbreviations:........................................................................................................................ 192
2.2 Definitions: ............................................................................................................................ 192
3. General ......................................................................................................192
4. Field Computer Unit .....................................................................................192
4.1 Connectors............................................................................................................................. 192
4.2 Field Computer Preventive Maintenance.............................................................................. 192
4.2.1 Inspection for Damages ................................................................................................. 192
4.2.2 Inspection of EEx-d Enclosure Sealing ........................................................................... 192
4.3 Functional Check.................................................................................................................... 194
4.4 Remote System Performance Diagnostics............................................................................. 195
5. Transducers and Ball Valves .........................................................................195
5.1 Applicable for Transducer Full Size (TFS) ............................................................................... 195
6. Cables .......................................................................................................195
7. Lubrication .................................................................................................196
8. References .................................................................................................196
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1. Purpose
The purpose of this procedure is to describe the necessary maintenance and
preventive maintenance for the Fluenta Flare Gas Meter, FGM 160.
2.1 Abbreviations:
FGM Flare Gas Meter
O&SC Operator & Service Console
2.2 Definitions:
N/A
3. General
The FGM 160 requires only minimum maintenance. It is a system with no mechanical
moving parts. Maintenance is carried out if an error is detected or suspected to have
occurred. In addition, Fluenta strongly recommends a periodical maintenance routine
to secure the operational uptime of the meter. Below checks are standard procedure.
Take contact with Fluenta Service&Support for more information or booking of
maintenance.
The instructions are given for each major component in the flare gas metering system
and the time periods between each activity is also specified.
4. Field Computer Unit

Every six months the following should be checked:
4.1 Connectors
Check that all connectors in the EEx-e housing are properly connected and that there
is no corrosion or contamination on the terminals.
4.2 Field Computer Preventive Maintenance

Every twelve months the following should be carried out:
4.2.1 Inspection for Damages

Inspect the FGM 160 housing for damages. Make sure that the EEx-e housing draining
is operating as intended and that there is no contamination on the inside.
4.2.2 Inspection of EEx-d Enclosure Sealing

The EEx-d enclosure shall be inspected at least once every 12 months, in order to
ensure that the explosion proof sealing is not damaged. The inspection should be
carried out under conditions that will NOT lead to any moisture inside the EEx-d
72.120.606/D Page 192 of 211

enclosure. Carefully remove the sunshield and put it in a safe place to ensure no
damage while working with the EEx-d enclosure, ref. Figure 103.
1) Use the universal opener tool shown below for loosening first only the black top
Ex-d part of the EEx-d enclosure by turning counterclockwise.
2) After inspection of the O-ring (126,67 x 2,62mm) and the threads, put copper
paste on the threads before carefully sliding the top part back in position.
3) Use the universal opener tool shown below for loosening now the pipe Ex-d part
(incl. top Ex-d) by turning the pipe counterclockwise.
4) Remove the electronics stack to inspect the O-ring (126,67 x 2,62mm) in the
bottom. Caution: ESD safety must be in place! Inspect also threads.
5) Re-mount the electronics stack.
6) Put copper paste on the threads before carefully sliding the pipe Ex-d part back
in position.
7) Re-install the sunshield in order to complete the operation.
Note: Should replacement of the O-rings be necessary the new O-rings (126,67 x
2,62mm) must be slightly expanded for optimal fitting.
Figure 103 FGM 160 with description of how to dismount the Ex-d enclosure.
The EEx-d housing should under normal circumstances not be opened. However, if
required, the work should be performed in a work-shop in Safe Area or under good
weather conditions.
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If this operation must be carried out in field (hazardous area), a hot

working permission must be issued prior to starting this work. Further,
take notice of the warning on the Ex-d enclosure, regarding opening
the Ex-d enclosure when explosive gas atmosphere is present, ref.
Figure 104.
Considerations to weather and environments must then be taken. Never reassemble

the EEx-d housing without replacing the gasket and the silica gel package.
Figure 104 FGM 160 WARNING label regarding opening the Ex-d enclosure when an
explosive gas atmosphere is present.
4.3 Functional Check

Every twelve months or after shutdown the following should be carried out:
Check all meter functions and if any indications of malfunction, go through the Factory
Acceptance Test Procedure for FGM 160, Fluenta doc. no. 62.120.003. This should
preferably be carried out by Fluenta personnel, generally in collaboration with
personnel responsible for daily operation of the system.
In addition to the procedure already mentioned above, a reliable zero point check and
if required, adjustment for the different transmitted ultrasonic signals should be
carried out. Fluenta service personnel are making use of a portable, special designed
box for this purpose.
Different signals will also be analyzed by Fluenta personnel, using the Operator &
Service Console (O&SC) program. The O&SC displays important information of how
the system operates, and how to troubleshoot potential errors, as the signals can be
interpreted, compared and optimized if necessary.
Using experienced and qualified Fluenta personnel once a year to run a total system
functionality check is recommended as this will decrease the possibility for a system
malfunction and increase the system reliability.
72.120.606/D Page 194 of 211

4.4 Remote System Performance Diagnostics

By operating the O&SC remotely, remote system performance diagnostics can be
carried out. This can either be carried out by the operator or by Fluenta through a
remote support agreement.
RS485-TCP/IP
converter, or
Remote
Control
Software
Haz. Area Local Remote
Figure 105 Local and remote control of the FGM 160 Field Computer by using the Operator &
Service Console software.
5. Transducers and Ball Valves

5.1 Applicable for Transducer Full Size (TFS)
Every six months or after shutdown the following should be checked:
· Make sure that all nuts and bolts between the transducer holder and the ball valve
and between the ball valve and the transducer unit are properly tightened.
· All flanges must be parallel.
· Check that the ball valves are open (not in contact with the transducers).
· Check that the nut (on fitting) at the end of the packing box is tight.
6. Cables
Inspect transducer cables and the FGM 160 cables for damages. Make sure that the
cables do not have any sharp bends and ensure that there is no contact between the
cables and sharp edges that can cause damages. Interfering equipment in the
72.120.606/D Page 195 of 211
surroundings must be kept in a safe distance from the cables and the rest of the FGM
160 equipment.
7. Lubrication
Refer to 4.2.2 for parts that need lubrication as preventive maintenance.
8. References
N/A
72.120.606/D Page 196 of 211

Spare Parts List
8. SPARE PARTS LIST
8.1 SPIR ............................................................................................................. 198
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8.1 SPIR
72.120.606/D Page 198 of 211

Drawings
9. DRAWINGS
9.1 General Arrangement Flow Element - TFS ......................................................... 200

9.2 General Arrangement Sensor Unit – TFS with Lemo Insert Cable Connector ........... 201
9.3 Transducer Holder, 2”, ANSI 150# RF ............................................................... 202
9.4 Field Wiring Diagram, 1 System ....................................................................... 203
9.5 Block Diagram, 1 System ................................................................................ 209
9.6 General Arrangement Field Computer ............................................................... 210
72.120.606/D Page 199 of 211

9.1 General Arrangement Flow Element - TFS
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9.2 General Arrangement Sensor Unit – TFS with Lemo Insert Cable Connector
72.120.606/D Page 201 of 211

9.3 Transducer Holder, 2”, ANSI 150# RF
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9.4 Field Wiring Diagram, 1 System
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9.5 Field Wiring Diagram with Foundation Fieldbus, 1 System
72.120.606/D Page 204 of 211

9.6 Field Wiring Instructions, 1 System
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72.120.606/D Page 208 of 211
9.7 Block Diagram, 1 System
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9.8 General Arrangement Field Computer
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10. REVISION HISTORY
Document number: 72.120.606/D
Document Name: Complete User Manual

for FGM160-II
Scope: ISO 9001:2008 §7.2.3
Additional Information (when applicable)
Field Wiring diagram/instructions updated, FF field wiring

D 2012.01.03 added. Layout changes, FGM data sheet update, Ex- KES BSn KES BSn JJB
certification markings update.
C 2011.09.05 Fieldbus implemented JJB MW KE JJB JJB
B 2011.08.31 Changed to default settings JJB KED KE JJB JJB
A 2011.04.06 Issued for Fluenta release GA CKr KE JJB JJB
Rev. Review
Issue date Reason for issue Author Review Review Approved
index by QA
Replacement for:
211
Total no. of pages:
Fluenta doc. Ref:
72.120.606/D
Page 211 of 211

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Flare Gas Meter 160-II

Ultrasonic Flare Metering System

FLUENTA © 2010 www.fluenta.com info@fluenta.com sales@fluenta.com support@fluenta.com

Fluenta – Flare Gas Meter 160

Table Of Contents .......................................................................................... 2

72.120.606/D Page 2 of 211

· Fluenta is the world leader in ultrasonic flare metering, headquartered in

72.120.606/D Page 3 of 211

1.1 It all began in 1982

9th May 2007.

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1.2 The Fluenta FGM 160

· The FGM 160 is an Ultrasonic meter based on Time-of-Flight transit time

72.120.606/D Page 5 of 211

1.3 Fluenta Quality Assurance

Quality Management System (QMS)

Health, Safety & Environment Management

ISO 9001:2008 Certified

1.4 Company and Contact Information

72.120.606/D Page 6 of 211

2.1 Service & Commissioning ............................................................................... 8

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2.1 Service & Commissioning

2.1 Use of Meter Simulator to test the communication

2.2 Installation (Pre commissioning)

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· Communicat ion verification checks between field computer and client

2.4 Commissioning Spare Parts

3.1 Assistance from the Fluenta Support Team

3.2 Tailor-made Preventive Maintenance and Calibration

3.3 Regular Maintenance and training

3.4 Co-operation synergies leading to a priority customer

2.2 FGM 160 Training Courses

· Standard presentation (included in the price)

1.2 Recommended equipment for the course (at additional

72.120.606/D Page 10 of 211

· 1 – 2 days (depends on number of participants)

2. Extended operator course

· Standard presentation (included in the price)

2.2 Indispensible equipment for the course

Note: This course requires a s igned agreement with each of the

· 2 – 3 days (depends on number of participants)

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3. Field training course

Brief technical introduction to FGM 160, including operato r console

· Field training (“I n situ” customers’ location)

3.3 Minimum requirements for the course (at additional

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3.1 Utility Consumption Data

3.2 FGM 160 Data Sheet

3.3 Weight Data Sheet

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3.1 Utility Consumption Data

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3. Utility Consumption Data

4. Nominal Power Consumption

5. Maximum Power Consumption

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3.2 FGM 160 Data Sheet

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4.1 Pipe Sizes STANDARD OPTIONAL

6.1 Supply Voltage STANDARD OPTIONAL

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Each output channel can individually be set to one of the